Autonomous cleaner

ABSTRACT

A robot cleaner comprising: a cleaner body including a wheel unit and a controller controlling driving of the wheel unit; a suction unit disposed to protrude from the cleaner body, the suction unit sucking air containing dust; and a sensing unit disposed at the front of the cleaner body in which the suction unit is disposed, wherein at least one portion of the sensing unit is disposed to overlap with the suction unit in the top-bottom direction of the cleaner body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119 to Korean Application No. 10-2016-0062415, filed in Republic of Korea on May 20, 2016, Korean Application No. 10-2016-0072690, filed in Republic of Korea on Jun. 10, 2016, Korean Application No. 10-2016-0141106, filed in Republic of Korea on Oct. 27, 2016, Korean Application No. 10-2016-0109317, filed in Republic of Korea on Aug. 26, 2016, and Korean Application No. 10-2016-0184446, filed in Republic of Korea on Dec. 30, 2016, whose entire disclosures are hereby incorporated by reference.

BACKGROUND 1. Field

The present disclosure relates to a robot cleaner and/or autonomous cleaner.

2. Background

In general, robots have been developed for industrial purposes to play a role in factory automation. Recently, application fields of robots have extended, and robots for medical purpose, space navigation robots, etc., and even home robots available that may be used in general houses have been developed.

A representative example of home robots is a robot cleaner. The robot cleaner performs a function of cleaning a floor while traveling by itself in a certain area. For example, a household robot cleaner is configured to suck dust (including foreign substances) on a floor or mop the floor while autonomously traveling inside a house.

Such a robot cleaner generally includes a rechargeable battery and various sensors for avoiding an obstacle during traveling. Thus, the robot cleaner performs a cleaning function while traveling by itself.

In order to allow the autonomous traveling of a robot cleaner to be smoothly performed, it is important to set the entire traveling route and sense obstacles on the traveling route. The robot cleaner may also perform a function of photographing or monitoring the inside of a house using autonomous traveling characteristics thereof. In order to perform the above-described functions, various sensors are used in the robot cleaner, but studies for an optimized design have not been satisfactory yet.

In addition, a typical robot cleaner has a structure in which a suction unit is provided at a lower portion of a cleaner body. However, the structure in which the suction unit is built in the cleaner body has problems in that the suction force of the robot cleaner is decreased, that the separation of a brush roller is impossible, and the like. Accordingly, there has been proposed a structure in which a suction unit is provided to protrude from a cleaner body as disclosed in the following patent documents. However, the structure has many problems to be solved in that the probability of collision between the suction unit and an obstacle is increased, that the suction unit is located in a blind spot of a sensing unit provided in the cleaner body, and the like.

In a structure in which a dust container is coupled to a cleaner body, and a dust container cover is coupled to the dust container, it is important to accurately assemble the components and easily perform the assembly. However, any product having the structure has not been released yet.

In addition, air introduced into a robot cleaner typically passes through a HEPA filter for filtering fine dust before the air is discharged through an exhaust port. In the existing robot cleaners, there is an inconvenience that a portion of a cleaner body should be disassembled so as to replace or clean the HEPA filter.

Various robot cleaners are described in the following documents:

Patent Document 1: U.S. Patent Laid-Open Publication No. US 2013/0305484 A1 (published on Nov. 21, 2013);

Patent Document 2: U.S. Patent Laid-Open Publication No. US 2013/0061420 A1 (published on Mar. 14, 2013); and

Patent Document 3: U.S. Patent Laid-Open Publication No. US 2013/0061417 A1 (published on Mar. 14, 2013).

The above references are incorporated by reference herein where appropriate for appropriate teachings of additional or alternative details, features and/or technical background.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:

FIG. 1 is a perspective view illustrating an example of a robot cleaner according to an embodiment;

FIG. 2 is a plan view of the robot cleaner shown in FIG. 1;

FIG. 3 is a side view of the robot cleaner shown in FIG. 1;

FIG. 4 is a view illustrating a sensing unit shown in FIG. 1;

FIG. 5 is an exploded perspective view of the sensing unit shown in FIG. 4;

FIG. 6 is a view illustrating a section of the sensing unit shown in FIG. 4;

FIG. 7 is a view illustrating separation of an image photographed by a first sensing part shown in FIG. 6;

FIG. 8 illustrates sensing of an obstacle by a second sensing part shown in FIG. 4;

FIG. 9 is a block diagram illustrating main parts related to avoidance of an obstacle using the second sensing part;

FIG. 10 is a view illustrating a beam irradiation range of first and second pattern irradiating parts and an obstacle detection range of an image acquisition part;

FIG. 11 is a view illustrating a beam having a first pattern, irradiated by the first pattern irradiating part;

FIG. 12 is a view illustrating shapes of first and second beam patterns irradiated onto each obstacle for each shape of the obstacle.

FIG. 13 is a view illustrating a suction unit shown in FIG. 1;

FIG. 14 is a side view of the suction unit shown in FIG. 13;

FIG. 15 is a front view of the suction unit shown in FIG. 13;

FIG. 16 is a view illustrating a bottom portion of the suction unit shown in FIG. 13;

FIG. 17 illustrates a brush roller protruding through a manipulation of a manipulation part in the suction unit shown in FIG. 13;

FIG. 18 illustrates a flow of air inside the robot cleaner shown in FIG. 1;

FIG. 19 is a view illustrating a state in which a dust container is mounted in a dust container accommodation part in the robot cleaner shown in FIG. 1;

FIG. 20 is a view illustrating the dust container shown in FIG. 1;

FIG. 21 is an exploded perspective view illustrating main parts of the dust container illustrated in FIG. 20;

FIG. 22 is a bottom view of the dust container shown in FIG. 20;

FIG. 23 is a view illustrating a state in which the dust container is mounted in the dust container accommodation part shown in FIG. 19;

FIG. 24 is a front view of the dust container shown in FIG. 20;

FIGS. 25 and 26 are perspective views of a flow separation member illustrated in FIG. 24, viewed from different directions;

FIG. 27 is a sectional view taken along the line A-A of FIG. 24;

FIG. 28 is a left side view of the dust container of FIG. 20;

FIG. 29 is a view illustrating the dust container of FIG. 20, excluding the upper case;

FIG. 30 is a view illustrating a state in which an upper case and an upper cover are separated from the dust container shown in FIG. 20;

FIG. 31 is a view illustrating a dust container cover shown in FIG. 1;

FIG. 32 is an exploded perspective view of the dust container cover shown in FIG. 31;

FIG. 33 is a view illustrating a rear surface of the dust container cover shown in FIG. 31;

FIG. 34 is a sectional view illustrating a structure in which a hook part shown in FIG. 33 is fastened to the dust container;

FIG. 35 is a view illustrating an inside of the dust container accommodation part shown in FIG. 19;

FIG. 36 is a view illustrating a state in which a filter unit shown in FIG. 35 is rotated; and

FIG. 37 is an exploded perspective view of the filter unit shown in FIG. 36.

DETAILED DESCRIPTION

Referring to FIGS. 1 to 3, the robot cleaner 100 cleans a floor while traveling autonomously in a certain area. The cleaning of the floor includes sucking foreign substances, e.g., debris, dust, fine dust, ultrafine dust, etc., of the floor or mopping the floor. The robot cleaner 100 includes a cleaner body 110, a suction unit 120 (e.g. cleaner head), a sensing unit or module 130, and a dust container 140. The cleaner body 110 is provided with a controller for controlling the robot cleaner 100 and wheels 111 for allowing the robot cleaner 100 to travel. The robot cleaner 100 may be moved in all directions or be rotated by the wheels 111.

The wheels 111 includes main wheels 111 a and a sub-wheel 111 b. The main wheels 111 a are provided at both sides of the cleaner body 110 to be rotatable in one direction or the other direction according to a control signal of the controller. The main wheels 111 a may be configured to be driven independently from each other. For example, the main wheels 111 a may be driven by different driving motors, respectively. The sub-wheel 111 b supports the cleaner body 110 together with the main wheels 111 a, and is configured to assist traveling of the robot cleaner 100 through the main wheels 111 a. The sub-wheel 111 b may also be provided in the suction unit 120. The controller controls the driving of the wheels 111, such that the robot cleaner 100 autonomously travels on the floor.

A battery 180 (FIG. 18) supplies power to the robot cleaner 100 and is mounted in the cleaner body 110. The battery 180 is rechargeable and may be configured to be attachable/detachable to/from a bottom surface of the cleaner body 110.

The suction unit 120 is provided in a shape protruding from one side of the cleaner body 110 to suck air containing foreign substances. The one side may be a side at which the cleaner body 110 travels in a forward direction F, i.e., the front of the cleaner body 110. The suction unit 120 may have a shape protruding frontward, leftward, and rightward at the one side of the cleaner body 110. A front end portion of the suction unit 120 may be provided at a position spaced apart forward from the one side of the cleaner body 110, and both left and right end portions of the suction unit 120 are provided at positions spaced apart leftward and rightward from the one side of the cleaner body 110, respectively.

As the cleaner body 110 is formed in a circular shape, and both sides of a rear end portion of the suction unit 120 are respectively formed to protrude leftward and rightward from the cleaner body 110, empty spaces, i.e., gaps may be formed between the cleaner body 110 and the suction unit 120. The empty spaces are spaces between both left and right end portions of the cleaner body 110 and both left and right end portions of the suction unit 120, and have a shape recessed inward of the robot cleaner 100.

When an obstacle is inserted into the empty space, a problem may occur where the robot cleaner 100 is caught by the obstacle and may stop movement. In order to prevent this problem, a cover member 129 or a flap of a plate or wedge shape may be provided to cover at least one portion of the empty space. The cover member 129 may be provided to the cleaner body 110 or the suction unit 120. In this embodiment, the cover members 129 may protrude from both sides of the rear end portion of the suction unit 120 to cover outer circumferential surfaces of the cleaner body 110, respectively.

The cover members 129 are provided to fill in the empty space, i.e., at least one portion of the empty spaces between the cleaner body 110 and the suction unit 120. The cover member 129 is provided to fill in at least one portion of spaces recessed inward between left and right outer circumferential surfaces of the cleaner body 110 formed in a curve and both left and right end portions of the suction unit 120 formed to protrude from the respective left and right outer circumferential surfaces. The structure of the cover member 129 may prevent an obstacle from being caught in the empty space or may allow escape from an obstacle even when the obstacle is caught in the empty space.

The cover member 129 formed to protrude from the suction unit 120 may be supported by the outer circumferential surface of the cleaner body 110. When the cover member 129 is formed to protrude from the cleaner body 110, the cover member 129 may be supported by a rear surface portion of the suction unit 120. When the suction unit 120 collides with an obstacle and receives an impact from the obstacle, a portion of the impact is transferred to the cleaner body 110, such that the force of impact may be distributed.

The suction unit 120 may be detachably coupled to the cleaner body 110. The suction unit 120 may be swapped with a mop module. When a user intends to remove dust of a floor, the user may mount the suction unit 120 to the cleaner body 110. When the user intends to mop the floor, the user may mount the mop module to the cleaner body 110.

When the suction unit 120 is mounted to the cleaner body 110, the mounting may be guided by the cover members 129. The cover members 129 are provided to cover the outer circumferential surface of the cleaner body 110 such that a relative position of the suction unit 120 with respect to the cleaner body 110 can be determined and/or aligned.

The sensing unit 130 (sensor module) is provided at the cleaner body 110. The sensing unit 130 may be provided at one side of the cleaner body 110, i.e., the front of the cleaner main body 110. The sensing unit 130 may protrude from top and side surfaces of the cleaner body 110, and an upper end 134 b 1 (FIG. 5) of the sensing unit 130 is formed at a position protruding upward from the top surface of the cleaner body 110.

The sensing unit 130 may be provided to overlap with the suction unit 120 in the top-bottom direction of the cleaner body 110. The sensing unit 130 is provided above the suction unit 120 to sense an obstacle and/or geographic feature at the front thereof such that the suction unit 120 located foremost of the robot cleaner 100 does not collide with the obstacle and/or geographic feature. The sensing unit 130 is configured to additionally perform another sensing function other than a sensing function, which will be described in detail hereinafter.

A dust container accommodation part 113 (recess) is provided in the cleaner body 110, and the dust container 140 that separates and collects foreign substances of the sucked air is detachably coupled to the dust container accommodation part 113. The dust container accommodation part 113 may be formed at the other side of the cleaner body 110, e.g., the rear of the cleaner body 110. The dust container accommodation part 113 has a shape opened rearward and upward from the cleaner body 110. The dust container accommodation part 113 may be formed in a shape dented toward rear and front sides of the cleaner body 110.

A portion or front of the dust container 140 is accommodated in the dust container accommodation part 113. In this case, the other portion or rear of the dust container 140 may be formed to protrude toward the rear of the cleaner body 110 (i.e., in a reverse direction R opposite to the forward direction F).

An entrance 140 a (see FIG. 20) through which air containing dust is introduced and an exit 140 b (see FIG. 20) through which air having dust separated therefrom is discharged are formed in the dust container 140. When the dust container 140 is mounted in the dust container accommodation part 113, the entrance or inlet 140 a and the exit or outlet 140 b are configured to respectively communicate with a first opening 110 a (see FIG. 19) and a second opening 110 b (see FIG. 19), which are formed in an inner wall of the dust container accommodation part 113.

An intake flow path in the cleaner body 110 corresponds to a flow path from an introduction port 110′ communicating with a communication part 120 b″ to the first opening 110 a, and an exhaust flow path in the cleaner body 110 corresponds to a flow path from the second opening 110 b to an exhaust port 112. See FIG. 18.

According to such an air flow connection relationship, air containing foreign substances, which is introduced through the suction unit 120, is introduced into the dust container 140 via the intake flow path in the cleaner body 110, and the foreign substances are separated from the sucked air by passing through at least one cyclone provided in the dust container 140. The foreign substances, e.g., dust is collected in the dust container 140, and the air is discharged from the dust container 140. The filtered air is discharged to the outside through the exhaust port 112 by passing through the exhaust flow path in the cleaner body 110.

Referring to FIGS. 4 to 6, the sensing unit 130 includes a first sensing part 131 and a second sensing part 132. The first sensing part 131 (first image sensor) is provided inclined with respect to one surface of the cleaner body 110 to simultaneously photograph front and upper parts of the cleaner body 110. A camera may be used as the first sensing part 131. The camera may be inclined relative to a floor surface as a surface parallel to the floor, or the top or side surface of the cleaner body 110. For example, the first sensing part 131 may be provided inclined at 30 degrees with respect to the top surface of the cleaner body 110.

The first sensing part 131 may be located at an upper corner portion at which the top and side surfaces of the cleaner body 100 meet each other. For example, the first sensing part 131 may be provided at a middle upper corner portion of the cleaner body 110 to be inclined with respect to each of the top and side surfaces of the cleaner body 110. As the first sensing part 131 is provided inclined within a range of acute angles with respect to the one surface of the cleaner body 110, the sensing part 131 is configured to simultaneously photograph the front and upper parts of the cleaner body 110.

FIG. 7 in conjunction with FIG. 6 illustrates an image photographed by the first sensing part 131, which is divided into a front image A and an upper image B. The front image A and the upper image B, may be divided based on an angle α of view (field of view) in the top and bottom direction) of the first sensing part 131. An image corresponding to a portion α1 of the angle α of view in the photographed image A+B may be recognized as the front image A, and an image corresponding to the other portion α2 of the angle α of view in the photographed image A+B may be recognized as the upper image B. As shown in FIG. 6, the angle α of view may be an obtuse angle.

The front image A photographed by the first sensing part 131 is used to monitor the front in real time. For example, when the robot cleaner 100 is used for household purposes, the front image A photographed by the first sensing part 131 may be used for monitoring or to provide an image of the inside of the house to an electronic device (e.g., a mobile terminal possessed by the user) through a remote connection.

When the front image A photographed by the first sensing part 131 is used for monitoring a house, the following control or operational mode may be performed. The controller may compare fronts images A photographed by the first sensing part 131 at a preset time interval. When the front images A are different from each other, the controller may generate a control signal. The control may be performed in a state in which the cleaner body 110 is stationary. The control signal may be an alarm sound output signal or a transmission signal that provides a notification, a photographed front image, and the like to the electronic device through the remote connection.

When the front image A photographed by the first sensing part 131 is used to provide an image of the inside of the house to the electronic device, the following control or operational mode may be performed. When an image request signal is received by the robot cleaner from the electronic device through the remote connection, the controller may ascertain a front image A from an image photographed by the first sensing part 131 and transmit the front image A to the electronic device. The robot cleaner may be configured to move to a specific position by controlling driving of the wheel unit 111 and then transmit a front image at the corresponding position to the electronic device.

As shown in FIG. 6, the angle α of view may have a range in which the first sensing part 131 can photograph the upper image B including a ceiling. The upper image B photographed by the first sensing part 131 is used to generate a map of a traveling area and sense or determine a current position in the traveling area. For example, when the robot cleaner 100 is used for household purposes, the controller may generate a map of a traveling area, using a boundary between a ceiling and a side surface in the upper image B photographed by the first sensing part 131, and sense or determine a current position in the traveling area based on main feature points of the upper image B. The controller may use both upper image B and the front image A to generate a map of a traveling area and sense or determine a current position in the traveling area.

The second sensing part 132 (second sensor) is provided in a direction intersecting the first sensing part 131 to sense an obstacle or geographic feature located at the front thereof. The second sensing part 132 may be provided along the top-bottom direction at the side surface of the cleaner body 110. The second sensing part 132 includes a first pattern irradiating part or a first light source 132 a, a second pattern irradiating part or a second light source 132 b, and an image acquisition part or an image sensor 132 c.

The first pattern irradiating part 132 a is configured to irradiate a beam having a first pattern toward a front lower side or front bottom direction of the robot cleaner 100, and the second pattern irradiating part 132 b is configured to irradiate a beam having a second pattern toward a front upper side or front upper direction of the robot cleaner 100. The first pattern irradiating part 132 a and the second pattern irradiating part 132 b may be provided in a line along the top-bottom direction of the cleaner body. As an example, the second pattern irradiating part 132 b is provided under or below the first pattern irradiating part 132 a.

The image acquisition part or second image sensor 132 c is configured to photograph, in a preset photographing area, the beams having the first and second patterns, which are respectively irradiated by the first pattern irradiating part 132 a and the second pattern irradiating part 132 b. The preset photographing area includes an area from the floor to an upper end of the robot cleaner 100. The robot cleaner 100 may sense or detect an obstacle at the front thereof, and it is possible to prevent the robot cleaner 100 from colliding with an upper portion of the cleaner body being stuck or colliding with an obstacle.

The preset photographing area may be, for example, an area within an angle of view of 105 degrees in the top-bottom direction (i.e., the vertical direction), an angle of view of 135 degrees in the left-right direction (i.e., the horizontal direction), and the front of 25 m relative to the cleaner body. The preset photographing area may be changed depending on various factors such as installation positions of the first and second pattern irradiating parts 132 a and 132 b, irradiation angles of the first and second pattern irradiating parts 132 a and 132 b, and a height of the robot cleaner 100.

The first pattern irradiating part 132 a, the second pattern irradiating part 132 a, and the image acquisition part 132 c may be provided in a line along the top-bottom direction of the cleaner body 110. As illustrated, the image acquisition part 132 c is provided under the second pattern irradiating part 132 b. The first pattern irradiating part 132 a is provided to be downwardly inclined with respect to the side surface of the cleaner body 110, and the second pattern irradiating part 132 b is provided to be upwardly inclined with respect to the side surface of the cleaner body 110.

Referring to (a) of FIG. 8, the first pattern irradiating part 132 a and the second pattern irradiating part 132 b are configured to respectively irradiate beams having first and second patterns that have a shape extending at least one direction. As illustrated, the first pattern irradiating part 132 a irradiates linear beams intersecting each other and the second pattern irradiating part 132 b irradiates a single linear beam. Accordingly, a bottommost beam is used to sense an obstacle at a bottom portion, a topmost beam is used to sense an obstacle at a top portion, and a middle beam between the bottommost beam and the topmost beam is used to sense an obstacle at a middle portion.

For example, as shown in (b) of FIG. 8, when an obstacle O is located at the front, the bottommost beam and a portion of the middle beam may be interrupted or distorted by the obstacle O. When such interruption or distortion is sensed, the image acquisition part 132 c transmits an obstacle sensing signal to the controller.

If the obstacle sensing signal is received, the controller determines that the obstacle O is located, and controls the driving of the wheel unit 111. For example, the controller may apply a driving force in the opposite direction to the main wheels 111 a such that the robot cleaner 100 moves rearward. Alternatively, the controller may apply the driving force to only any one of the main wheels 111 a such that the robot cleaner 100 rotates, or apply the driving force to both the main wheels 111 a in directions different from each other.

FIG. 9 is a block diagram illustrating main parts or components related to avoidance of an obstacle using the second sensing part 132. The robot cleaner 100 includes the wheel unit 111, a data part or storage device 191, a second sensing part 132, and a controller 190 that controls overall operations.

The controller 190 may include a traveling or movement controller 190 c that controls the wheel unit 111. As a left main wheel 111 a and a right main wheel 111 a are independently driven by the traveling controller 190 c, the robot cleaner 100 may move in a straight direction or rotate left or right. A driving motor of which driving is controlled according to a control command of the traveling controller 190 c may be connected to each of the left main wheel 111 a and the right main wheel 111 a.

The controller 190 may include a pattern detection part or pattern detector 190 a that detects a pattern by analyzing data input from the second sensing part 132 and an obstacle information acquisition part or module 190 b that determines whether an obstacle exists from the detected pattern. The pattern detection part 190 a detects beam patterns P1 and P2 from an image (acquired image) acquired by the image acquisition part 132. The pattern detection part 190 a may detect features of points, lines, surfaces, and the like with respect to predetermined pixels constituting the acquired image, and detect the beam patterns P1 and P2 or points, lines, surfaces, and the like, which constitute the beam patterns P1 and P2. The obstacle information acquisition part 190 b determines whether an obstacle exists based on the patterns detected from the pattern detection part 190 a, and determine a shape of the obstacle.

The data part 191 stores reference data that stores an acquired image input from the second sensing part 132 and allows the obstacle information acquisition part 190 b to determine whether an obstacle exists. The data part 191 stores obstacle information on a sensed obstacle. The data part 191 stores control data for controlling an operation of the robot cleaner 100 and data corresponding to a cleaning mode of the robot cleaner 100. The data part 191 stores a map generated or received from the outside. In addition, the data part 191 stores data readable by a microprocessor, and may include a hard disk driver (HDD), a solid state disk (SSD), a silicon disk drive (SDD), a ROM, a RAM, a CD-ROM, a magnetic tape, a floppy disk, and an optical data storage device.

The second sensing part 132 includes the first pattern irradiating part 132 a, the second pattern irradiating part 132 b, and the image acquisition part 132 c. The second sensing part 132 is installed at a front side of the cleaner body 110. In the second sensing part 132, the first and second pattern irradiating parts 132 a and 132 b irradiate beams P1 and P2 having first and second patterns toward the front of the robot cleaner 100, and the image acquisition part 132 c acquires an image by photographing the irradiated beams having the patterns.

The controller 190 stores an acquired image in the data part 191, and the pattern detection part 190 a extracts a pattern by analyzing the acquired image. The pattern detection part 190 a extracts a beam pattern obtained by irradiating a beam having a pattern, which is irradiated from the first pattern irradiating part 132 a or the second pattern irradiating part 132 b, onto a floor or obstacle. The obstacle information acquisition part 190 b determines whether an obstacle exists, based on the extracted beam pattern.

The controller 190 determines whether an obstacle exists through an acquired image input from the second sensing part 132 and controls the wheel unit 111 to travel while avoiding the obstacle by changing a moving direction or traveling route.

When a cliff (e.g., stairs) exists in the vicinity of the robot cleaner 100, the robot cleaner 100 may fall from the cliff. The controller 190 may sense the cliff through an acquired image, and reconfirm whether the cliff exists through a cliff sensor 124, to control the traveling of the robot cleaner 100 such that the robot cleaner 100 does not fall from the cliff. When it is determined that a cliff does exist, the controller 190 may control the wheel unit 111 to travel along the cliff by determining a change in beam pattern through an acquired image.

In addition, when the movement of the robot cleaner 100 may be restricted due to a plurality of obstacles existing in an area having a certain size or less, the controller 190 may determine whether the robot cleaner 100 is in a restricted situation, and set an escape mode such that the robot cleaner 100 avoids the restricted situation. The controller 190 may allow the robot cleaner 100 to avoid the restricted situation by setting an escape route based on information on each obstacle around the robot cleaner 100 according to whether a currently set mode is a fundamental mode or a fast cleaning mode.

For example, in the fundamental mode, the controller 190 may generate a map on a peripheral area by acquiring information on all obstacles around the robot cleaner 100 and then set an avoidance route. In the fast cleaning mode, the controller 190 may set an avoidance route by determining whether the robot cleaner 100 is to enter according to a distance between sensed obstacles.

The controller 190 determines a distance between sensed obstacles by analyzing a beam pattern of an acquired image with respect to the sensed obstacles, and determines that the robot cleaner 100 is to travel and enter when the distance between the obstacles is a certain value or more, to control the robot cleaner 100 to travel. Thus, the controller 190 enables the robot cleaner 100 to escape a restricted situation.

FIG. 10 is a view illustrating a beam irradiation range of the first and second pattern irradiating parts 132 a and 132 b and an obstacle detection range of the image acquisition part 132 c. Each of the first and second pattern irradiating parts 132 a and 132 b may include a beam source and an optical pattern projection element (OPPE) that generates a beam having a predetermined pattern as a beam irradiated from the beam source is transmitted therethrough.

The beam source may be a laser diode (LD), a light emitting diode (LED), or the like. Since a laser beam has characteristics of monochromaticity, straightness, and connectivity, the laser diode is superior to other beam sources, and thus can accurately measure a distance. In particular, since an infrared or visible ray has a large variation in accuracy of distance measurement depending on factors such as a color and a material of an object, the laser diode is used as the beam source.

A pattern generator may include a lens and a diffractive optical element (DOE). Beams having various patterns may be irradiated according to a configuration of a pattern generator provided in each of the first and second pattern irradiating parts 132 a and 132 b. The first pattern irradiating part 132 a may irradiate a beam P1 having a first pattern (hereinafter, referred to as a first pattern beam) toward a front lower side of the cleaner body 110. The first pattern beam P1 may be incident onto a floor of a cleaning area. The first pattern beam P1 may be formed in the shape of a horizontal line. The first pattern beam P1 may be formed in the shape of a cross pattern in which a horizontal line and a vertical line intersect each other.

The first pattern irradiating part 132 a, the second pattern irradiating part 132 b, and the image acquisition part 132 c may be vertically aligned. As illustrated, the image acquisition part 132 c is provided under the first pattern irradiating part 132 a and the second pattern irradiating part 132 b. However, the present disclosure is not necessarily limited thereto, and the image acquisition part 132 c may be provided above the first pattern irradiating part 132 a and the second pattern irradiating part 132 b.

The first pattern irradiating part 132 a may also sense an obstacle located lower than the first pattern irradiating part 132 a by downwardly irradiating the first pattern beam P1 toward the front, and the second pattern irradiating part 132 b may be located at a lower side of the first pattern irradiating part 132 a to upwardly irradiate a beam P2 having a second pattern (hereinafter, referred to as a second pattern beam) toward the front. The second pattern beam P2 may be incident onto an obstacle or a certain portion of the obstacle, which is located higher than at least the second pattern irradiating part 132 b from the floor of the cleaning area. The second pattern beam P2 may have a pattern different from that of the first pattern beam P1, and may be configured to include a horizontal line. The horizontal line is not necessarily a consecutive line segment but may be formed as a dotted line.

Meanwhile, a horizontal irradiation angle of the first pattern beam P1 irradiated from the first pattern irradiating part 132 a (e.g., an angle made by both ends of the first pattern beam P1 and the first pattern irradiating part 132 a) may be defined in a range of 130 degrees to 140 degrees, but the present disclosure is not necessarily limited thereto. The first pattern beam P1 may be formed in a shape symmetrical with respect to the front of the robot cleaner 100.

Like the first pattern irradiation part 132 a, a horizontal irradiation angle of the second pattern irradiating part 132 b may be defined in a range of 130 degrees to 140 degrees. In some other embodiments, the second pattern irradiating part 132 b may irradiate the second pattern beam P2 at the same horizontal irradiation angle as the first pattern irradiating part 132 a. In this case, the second pattern beam P2 may also be formed in a shape symmetrical with respect to the front of the robot cleaner 100.

The image acquisition part 132 c may acquire an image of the front of the cleaner body 110. The pattern beams P1 and P2 are shown in an image acquired by the image acquisition part 132 c (hereinafter, referred to as an acquired image). Hereinafter, images of the pattern beams P1 and P2 shown in the acquired image are referred to as beam patterns. Since the beam patterns are images formed as the pattern beams P1 and P2 incident onto an actual space are formed in an image sensor, the beam patterns are designated by the same reference numerals as the pattern beams P1 and P2. Images corresponding to the first pattern beam P1 and the second pattern beam P2 are referred to as a first beam pattern P1 and a second beam pattern P2, respectively.

The image acquisition part 132 may include a digital image acquisition part that converts an image of a subject into an electrical signal and then converts the electrical signal into a digital signal to be stored in a memory device. The digital image acquisition part may include an image sensor and an image processing part or processor.

The image sensor is a device that converts an optical image into an electrical signal, and is configured as a chip having a plurality of photo diodes integrated therein. An example of the photo diode may be a pixel. Electric charges are accumulated in each of the pixels by an image formed in the chip through a beam passing through a lens. The electric charges accumulated in the pixel are converted into an electric signal (e.g., a voltage). A charge coupled device (CCD), a complementary metal oxide semiconductor (CMOS), and the like are well known as the image sensor.

The image processing part generates a digital image, based on an analog signal output from the image sensor. The image processing part may include an AD converter that converts an analog signal into a digital signal, a buffer memory that temporarily records digital data according to the digital signal output from the AD converter, and a digital signal processor (DSP) that generates a digital image by processing the data recorded in the buffer memory.

The pattern detection part 190 a may detect features of points, lines, surfaces, and the like with respect to predetermined pixels constituting an acquired image, and detect the beam patterns P1 and P2 or points, lines, surfaces, and the like, which constitute the beam patterns P1 and P2. For example, the pattern detection part 190 a may extract a horizontal line constituting the first beam pattern P1 and a horizontal line constituting the second beam pattern P2 by extracting line segments configured as pixels brighter than surroundings are consecutive. However, the present disclosure is not limited thereto. Since various techniques of extracting a pattern having a desired shape from a digital image have already been well known in the art, the pattern detection part 190 a may extract the first beam pattern P1 and the second beam pattern P2 using these techniques.

The first pattern irradiating part 132 a and the second pattern irradiating part 132 b are vertically provided to be spaced apart from each other at a distance h3. The first pattern irradiating part 132 a downwardly irradiates a first pattern beam, and the second pattern irradiating part 132 b upwardly irradiates a second pattern beam, so that the first and second pattern beams intersect each other.

The image acquisition part 132 c is provided downward from the second pattern irradiating part 132 b at a distance h2 to photograph an image of the front of the cleaner body 110 at an angle θs of view with respect to the top-bottom direction. The image acquisition part 132 c is installed at a position spaced apart from the bottom surface at a distance h1. The image acquisition part 132 c may be preferably installed at a position that does not interfere with the photographing of an image of the front, by considering the shape of the suction unit 120.

Each of the first pattern irradiating part 132 a and the second pattern irradiating part 132 b is installed such that a direction in which the direction of optical axes of lenses constituting each of the first pattern irradiating part 132 a and the second pattern irradiating part 132 b forms a certain irradiation angle.

The first pattern irradiating part 132 a downwardly irradiates the first pattern beam P1 at a first irradiation angle θr1, and the second pattern irradiating part 132 b upwardly irradiates the second pattern beam P2 at a second irradiation angle θr2. The first irradiation angle θr1 and the second irradiation angle θr2 are basically different from each other, but may be set equal to each other in some cases. The first irradiation angle θr1 and the second irradiation angle θr2 may be preferably set in a range of 50 degrees to 75 degrees, but the present disclosure is not necessarily limited thereto. For example, the first irradiation angle θr1 may be set to 60 degrees to 70 degrees, and the second irradiation angle θr2 may be set to 50 degrees to 55 degrees. The first irradiation angle θr1 and the second irradiation angle θr2 may be changed depending on the shape of the suction unit 120 and the height of an upper portion to be sensed.

When a pattern beam irradiated from the first pattern irradiating part 132 a and/or the second pattern irradiating part 132 b is incident onto an obstacle, the positions of the beam patterns P1 and P2 in an acquired image may be changed depending on a position at which the obstacle is distant from the first pattern irradiating part 132 a. For example, when the first pattern beam P1 and the second pattern beam P2 are incident onto a predetermined obstacle, the first beam pattern P1 is displayed at a higher position in the acquired image as the obstacle is located closer to the robot cleaner 100. On the contrary, the second beam pattern P2 is displayed at a lower position in the acquired image as the obstacle is located more distant from the robot cleaner 100.

Data on distances to an obstacle, which correspond to rows (lines configured with pixels arranged in the lateral direction) constituting an image generated by the image acquisition part 132 c, is stored in advance. If the beam patterns P1 and P2 detected in the image acquired through the image acquisition part 132 c are detected on a predetermined row, a position of the obstacle may be estimated from data on a distance to the obstacle, which corresponds to the row. The angle θs of view of the image acquisition part 132 c may be set to a value of 100 degrees or more, and be preferably set to 100 degrees to 110 degrees. However, the present disclosure is not necessarily limited thereto.

In addition, the distance from the floor of the cleaning area to the image acquisition part 132 c may be set to about 60 mm to 70 mm. In this case, the floor of the cleaning area in the image acquired by the image acquisition part 132 c is shown posterior to D1 from the image acquisition part 132 c, and D2 is a position at which the first beam pattern P1 is displayed on the floor shown in the acquired image.

When an obstacle is located in D2, an image in which the first beam pattern P1 is incident onto the obstacle may be acquired by the image acquisition part 132 c. When the obstacle comes closer to the robot cleaner 100 than D2, the first optical pattern is displayed upward of a reference position ref1, corresponding to the incident first pattern beam P1.

The distance from the cleaner body 110 to D1 may be 100 mm to 150 mm, and the distance from the cleaner body 110 to D2 may be preferably 180 mm to 280 mm. However, the present disclosure is not necessarily limited thereto. Meanwhile, D3 represents a distance from a most protruding portion of the front of the cleaner body 110 to a position at which the second pattern beam is incident. Since the cleaner body 110 senses an obstacle during traveling, D3 is a minimum of distance at which the cleaner body 110 can sense the obstacle at the front (upper portion) thereof without colliding with the obstacle. D3 may be set to about 23 mm to 30 mm.

When the first beam pattern P1 shown in an acquired image disappears in a normal state during traveling of the cleaner body 110 or when a portion of the first beam pattern is displayed in the acquired image, the obstacle information acquisition part 190 b determines that a cliff exists in the vicinity of the robot cleaner 100.

When the first beam pattern P1 is not displayed in the acquired image, the obstacle information acquisition part 190 b may recognize that a cliff exists at the front of the robot cleaner 100. When a cliff (e.g., stairs) exists at the front of the robot cleaner 100, the first pattern beam is not incident onto the floor, and therefore, the first beam pattern P1 disappears in the acquired image.

The obstacle information acquisition part 190 b may determine that a cliff exists at the front distant by D2 from the cleaner body 110, based on a length of D2. In this case, when the first beam pattern P1 has a cross shape, the horizontal line disappears and only the vertical line is displayed. Therefore, the obstacle information acquisition part 190 b may determine that a cliff exists.

In addition, when a portion of the first beam pattern is not displayed, the obstacle information acquisition part 190 b may determine that a cliff exists at the left or right side of the robot cleaner 100. When a right portion of the first beam pattern is not displayed, the obstacle information acquisition part 190 b may determine that a cliff exists at the right side of the robot cleaner 100. Based on detected information on a cliff, the obstacle information acquisition part 190 b can control the wheel unit 111 to travel along a route on which the robot cleaner 100 does not fall from the cliff

When a cliff exists at the front of the robot cleaner 100, the traveling controller 190 c may again check whether a cliff exists, using a cliff sensor installed at a lower portion of the cleaner body 110, by moving forward by a certain distance, e.g., D2 or less. The robot cleaner 100 can primarily check whether a cliff exists through an acquired image and secondarily check whether a cliff exists through the cliff sensor.

FIG. 11 is a view illustrating a beam having a first pattern, irradiated by the first pattern irradiating part 132 a. The pattern detection part 190 a detects a first beam pattern or a second beam patter from an acquired image input from the image acquisition part 132 c and applies the first or second beam pattern to the obstacle information acquisition part 190 b. The obstacle information acquisition part 190 b analyzes the first or second beam pattern detected from the acquired image and compares a position of the first beam pattern with the reference position ref1, thereby determining whether an obstacle exists.

As shown in (a) of FIG. 11, when the horizontal line of the first beam pattern P1 is located at the reference position ref1, the obstacle information acquisition part 190 b determines that a current state is a normal state. The normal state is a state in which the floor is even and flat, and is a state in which the robot cleaner 100 can continuously travel as any obstacle does not exist at the front of the robot cleaner.

The second beam pattern P2 is incident onto an obstacle only when the obstacle exists at an upper portion of the front to be displayed in an acquired image. The second beam pattern P2 is not generally displayed in the acquired image in the normal state.

As shown in (b) of FIG. 11, when the horizontal line of the first beam pattern P1 is located above the reference position ref1, the obstacle information acquisition part 190 b determines that an obstacle exists at the front. If an obstacle is detected through the obstacle information acquisition part 190 b as described above, the traveling controller 190 c controls the wheel unit 111 to travel while avoiding the obstacle. Meanwhile, the obstacle information acquisition part 190 b may determine the position and size of the sensed obstacle, corresponding to the positions of the first and second beam patterns P1 and P2 and whether the second beam pattern P2 has been displayed. In addition, the obstacle information acquisition part 190 b may determine the position and size of the obstacle, corresponding to changes of the first and second beam patterns P1 and P2 displayed in the acquired image during traveling.

The traveling controller 190 c controls the wheel unit 111 by determining whether the wheel unit 111 is to continuously travel with respect to the obstacle or to travel while avoiding the obstacle, based on information of the obstacle, which is input from the obstacle information acquisition part 190 b. For example, when the height of the obstacle is lower than a certain height or less or when the cleaner body 110 is to enter into a space between the obstacle and the floor, the traveling controller 190 c determines that the traveling of the wheel unit 111 is possible.

As shown in (c) of FIG. 11, the first beam pattern P1 may be displayed at a position lower than the reference position ref1. When the first beam pattern P1 may be displayed at a position lower than the reference position ref1, the obstacle information acquisition part 190 b determines that a downhill road exists. In the case of a cliff, the first beam pattern P1 disappears, and therefore, the downhill road is distinguished from the cliff.

As shown in (d) of FIG. 11, the obstacle information acquisition part 190 b determines that a cliff exists in a traveling direction when the first beam pattern P1 is not displayed. As shown in (e) of FIG.11, when a portion of the first beam pattern P1 is not displayed, the obstacle information acquisition part 190 b may determines that a cliff exists at the left or right side of the cleaner body 110. In this case, the obstacle information acquisition part 190 b determines that a cliff exists at the left side of the cleaner body 110. Meanwhile, when the first beam pattern P1 has a cross shape, an obstacle may be determined by considering both the position of the horizontal line and the length of the vertical line.

FIG. 12 illustrates shapes of the first and second beam patterns P1 and P2 irradiated onto each obstacle for each shape of the obstacle. As beams irradiated from the first and second pattern irradiating parts 132 a and 132 b are incident onto an obstacle, so that beam patterns are shown in an acquired image, the obstacle information acquisition part 190 b may determine the position, size, and shape of the obstacle.

As shown in (a) of FIG. 12, when a wall surface exists at the front during traveling of the cleaner body 110, a first pattern beam is incident onto a floor and a second pattern beam is incident onto the wall surface. The first beam pattern P1 and the second beam pattern P2 are displayed as two horizontal lines in an acquired image. When a distance of the cleaner body 110 to the wall surface is longer than D2, the first beam pattern P1 is displayed at the reference position ref1, but the second beam pattern P2 is also displayed together with the first beam pattern P1. Therefore, the obstacle information acquisition part 190 b may determine that an obstacle exists.

Meanwhile, when the distance of the cleaner body 110 to the wall surface is less than D2, the first pattern beam is incident onto the wall surface instead of the floor. Therefore, the first beam pattern P1 is displayed at an upper side of the reference position ref1, and the second beam pattern P2 is displayed at an upper side of the first beam pattern P1. Since the position of the second beam pattern P2 is displayed at a lower side as the second beam pattern P2 approaches the obstacle, the second beam pattern P2 is displayed at a lower side as compared with when the distance of the cleaner body 110 to the wall surface is longer than D2. The second pattern beam P2 is displayed at an upper side as compared with the reference position ref1 and the first beam pattern P1. Accordingly, the obstacle information acquisition part 190 b can calculate a distance of the cleaner body 110 to the wall surface as an obstacle through the first beam pattern P1 and the second beam pattern P2.

As shown in (b) of FIG. 12, when an obstacle such as a bed or a dresser exists, the first beam pattern P1 and the second beam pattern P2 are incident as two horizontal lines onto a floor and an obstacle, respectively. The obstacle information acquisition part 190 b determines whether an obstacle exists, based on the first beam pattern P1 and the second beam pattern P2. The height of the obstacle may be determined based on a position of the second beam pattern P2 and a change of the second beam pattern P2, which occurs while the cleaner body 110 is approaching the obstacle. Accordingly, the traveling controller 190 c controls the wheel unit 111 by determining whether the cleaner body 110 is to enter into a lower space of the obstacle. For example, when an obstacle having a predetermined space formed from the floor, such as a bed in a cleaning area, is located, the traveling controller 190 c may recognize the space, and preferably determine whether to pass through or avoid the obstacle by detecting the height of the space.

When it is determined that the height of the space is lower than that of the cleaner body 110, the traveling controller 190 c may control the wheel unit 111 such that the cleaner body 110 travels while avoiding the obstacle. On the other hand, when it is determined that the height of the space is higher than that of the cleaner body 110, the traveling controller 190 may control the wheel unit 111 such that cleaner body 110 enters into or passes through the space.

Although the first beam pattern P1 and the second beam pattern P2 are displayed as two horizontal lines even in (a) of FIG. 12, a distance between the first beam pattern P1 and the second beam pattern P2 in (b) of FIG. 12 is different from that between the first beam pattern P1 and the second beam pattern P2 in (a) of FIG. 12. Therefore, the obstacle information acquisition part 190 b may distinguish the difference. In (a) of FIG. 12, the position of the first beam pattern P1 is displayed higher than the reference position ref1 as the first beam pattern approaches the obstacle. However, as shown in (b) of FIG. 12, when an obstacle is located above the cleaner body 110, the first beam pattern P1 is displayed at the reference position ref1 and the position of the second beam pattern P2 is changed even when they approach the obstacle by a certain distance. The obstacle information acquisition part 190 b may distinguish the kind of the obstacle.

As shown (c) of FIG. 12, in the case of a corner of an obstacle such as a bed or dresser, as the first beam pattern P1 is irradiated as a horizontal line onto a floor, and the second beam pattern P2 is irradiated onto the corner of the obstacle. As the second beam pattern P2 is irradiated onto the corner of the obstacle, a portion of the second beam pattern P2 is displayed as a horizontal line, and the other portion of the second beam pattern P2 is displayed as an oblique line. Since the position of the second beam pattern P2 becomes higher as the second beam pattern P2 is more distant from the cleaner body 110, the second beam pattern P2 irradiated onto a side surface of the obstacle is displayed as an oblique line bent upward of the horizontal line irradiated onto a front surface of the obstacle.

As shown in (d) of FIG. 12, when the cleaner body 110 approaches a corner of a wall surface by a certain distance or more, a portion of the first beam pattern P1 is displayed as a horizontal line at an upper side of the reference position ref1. As a portion of the second beam pattern P2 is irradiated onto a side surface of the corner, the portion of the second beam pattern P2 is displayed as an oblique line bent downward. As for a bottom surface, a portion of the second beam pattern P2 is displayed as a horizontal line at the reference position ref1.

Meanwhile, a portion of the second beam pattern P2 is displayed as a horizontal line as shown in (c) of FIG. 12, and a portion of the second beam pattern P2, which is irradiated onto the side surface of the corner, is displayed as an oblique line bent upward.

As shown in (e) of FIG. 12, in the case of an obstacle protruding from a wall surface, the first beam pattern P1 is displayed as a horizontal line as the reference position ref1. A portion of the second beam pattern P2 is displayed as a horizontal line on a protruding surface, another portion of the second beam pattern P2 is displayed as an oblique line bent upward on a side surface of the protruding surface, and the other portion of the second beam pattern P2 is displayed as a horizontal line on the wall surface.

Accordingly, the obstacle information acquisition part 190 b can determine the position, shape, and size (height) of an obstacle, based on the positions and shapes of first and second pattern beams.

Additional details of the first sensor and second sensor are disclosed in U.S. application Ser. No. 15/597,333 filed on May 17, 2017 (Attorney Docket No. PBC-0602) or Korean Application No. 10-2016-0060444 filed May 17, 2016, and Korean Application No. 10-2016-0014116 filed on Oct. 27, 2016, whose entire disclosure is incorporated herein by reference.

Referring to FIG. 5, the sensing unit 130 further includes a window part or assembly 133 and a case 134, in addition to the first sensing part 131 and the second sensing part 132. The window part 133 is provided to cover the first and second sensing parts 131 and 132, and has transparency. The transparency is a property that at least one portion of an incident beam is transmitted, and is translucent.

The window part 133 may be formed of a synthetic resin material or a glass material. When the window part 133 has the translucency, the material may be formed to have the translucency. Further, the material may have the transparency, and a film attached to the material may have the translucency.

The case 134 is mounted to the cleaner body 110, and is configured to fix the first and second sensing parts 131 and 132 and the window part 133. As shown in this figure, the case 134 is configured to accommodate at least one portion of the window part 133. The case 134 may be formed of a synthetic resin material or a metallic material, and has opaqueness.

As shown in this figure, the case 134 may include a mounting frame 134 a and the cover frame 134 b. The mounting frame 134 a provides a space in which the first and second sensing parts 131 and 132 are mounted and supported. The mounting frame 134 a may be provided with a first mounting part 134 a 1 (e.g., inclined protrusions) for mounting the first sensing part 131 thereto and a second mounting part 134 a 2 (e.g., tabs) for mounting the second sensing part 132 thereto. A board or a substrate 132′ on which the first and second pattern irradiating parts 132 a and 132 b and the image acquisition part 132 c are mounted may be mounted to the second mounting part 134 a 2. The second mounting part 134 a 2 may be provided inclined with respect to the first mounting part 134 a 1.

The mounting frame 134 a is provided with first and second fastening hooks 134 a′ and 134 a″ for allowing the mounting frame 134 a to be fastened to the cover frame 134 b and the window part 133. The first fastening hook 134 a′ is fastened to a fastening hole 134 b′ of the cover frame 134 b, and the second fastening hook 134 a″ is fastened to a fastening hole 133 b″ of the window part 133. The mounting frame 134 a may be mounted to the cleaner body 110.

The cover frame 134 b is mounted to the cleaner body 110 in a state in which the cover frame 134 b is coupled to the mounting frame 134 a and accommodates at least one portion of the window part 133. The cover frame 134 b may be formed in an ‘L’ shape to cover top and side surfaces of the cleaner body 110 at a corner of the cleaner body 110.

The upper end 134 b 1 of the cover frame 134 b is located at an upper side of the first sensing part 131, and may be formed inclined to have a sharp shape. According to the above-described shape, although the robot cleaner 100 is inserted into furniture or a gap during traveling thereof, the robot cleaner 100 can easily escape from the furniture or gap, and the first and second sensing parts 131 and 132 can be protected by the upper end 134 b 1 located upward of the first and second sensing parts 131 and 132. In this figure, a case where the upper end 134 b 1 is formed at an end portion of a hole 134 b″ which will be described later is illustrated as an example.

The first sensing part 131 and at least one portion of the second sensing part 132 may be accommodated in the hole 134 b″ formed inside the cover frame 134 b. As illustrated, the first sensing part 131 and the first and second pattern irradiating parts 132 a and 132 b of the second sensing part 132 are accommodated in the hole 134 b″.

The window part 133 may include a first window 133 a and a second window 133 b. The first window 133 a is formed of a transparent material, and is provided to cover the first sensing part 131. The second window 133 b is translucent, and is provided to cover the second sensing part 132. As illustrated, a through-hole 133 b′ may be formed at a portion of the second window part 133 b, which corresponds to the first sensing part 131, and the first window 133 a may be provided to cover the through-hole 133 b′.

As the first window 133 a is formed of a transparent material, images at the front and upper parts of the cleaner body 110 can be clearly photographed. Further, as the second window 133 b is translucent, the first pattern irradiating part 132 a, the second pattern irradiating part 132 b, and the image acquisition part 132 c on a rear surface of the second window 133 b are not noticeable by the naked eye from the outside for a clean appearance.

The second window 133 b may be divided in a first part 133 b 1 (first window cover), a second part 133 b 2 (second window cover), an extension part 133 b 4 (extension cover), and a third part 133 b 3 (third window cover).

The first part 133 b 1 is a part having the through-hole 133 b′, and is provided inclined with respect to the top surface of the cleaner body 110. The first window 133 a mounted in the through-hole 133 b′ is provided to cover the first sensing part 131.

The second part 133 b 2 downwardly extends in an inclined shape from the first part 133 b 1, and is provided to cover the first and second pattern irradiating parts 132 a and 132 b. As illustrated, the second part 133 b 2 downwardly extends in parallel to the side surface of the cleaner body 110.

The extension part 133 b 4 downwardly extends from the second part 133 b 2, and is covered by the cover frame 134 b. As illustrated, the extension part 133 b 4 may downwardly extend toward the inside of the second part 133 b 2. In other words, the extension part 133 b 4 may be provided upwardly inclined with respect to the third part 133 b 3 not to interfere with the angle of view in the top-bottom direction of the image acquisition part 132 c. Similarly, a portion of the cover frame 134 b, which covers the extension part 133 b 4, is provided inclined not to interfere with the angle of view in the top-bottom direction of the image acquisition part 132 c.

The third part 133 b 3 downwardly extends from the extension part 133 b 4 to protrude outward of the cover frame 134 b, and is provided to cover the image acquisition part 132 c. The third part 133 b 3 may downwardly extend in parallel to the second part 133 b 2 along the side surface of the cleaner body 110.

The suction unit 120 of FIG. 1 will be described in more detail with reference to FIGS. 13-16. When the suction unit 120 has a shape protruding from the cleaner body 110, it is likely that the suction unit 120 will collide with an obstacle unless a separate sensing unit is provided to the suction unit 120. The sensing unit 130 provided to the cleaner body 110 senses an obstacle at the front of the suction unit 120.

When an obstacle exists in a blind spot that the sensing unit 130 does not sense, a physical collision may occur between the robot cleaner 100 and the obstacle. When the physical collision occurs, the robot cleaner 100 is to move rearward or change a direction so as to avoid further collision with the obstacle. To avoid further collision, it is first required to sense the physical collision between the robot cleaner 100 and the obstacle.

The suction unit 120 includes a case 121 and a bumper switch 122 that senses the physical collision. The case 121 forms an appearance of the suction unit 120, and includes an inlet port 120 b′ that sucks air containing foreign substances, e.g., dust, and the communication part 120 b″ (air outlet port of the suction unit 120) communicating with the inhalation flow path in the cleaner body 110. At least one portion of the case 121 may have transparency such that the inside of the suction unit 120 may be viewable. The bumper switch 122 may be provided at at least one surface of the case 121. When the bumper switch 122 in contact with an obstacle, the bumper switch 122 is pressurized to transmit a contact signal to the controller. The bumper switch 122 may be also provided to surround the case 121. As illustrated, a front bumper switch 122 a is provided at a front side of the case 121, and side bumper switches 122 b and 122 c are provided at both left and right sides of the case 121, respectively. It is possible to sense not only a physical collision with an obstacle located at the front of the suction unit 120 but also a physical collision of an obstacle located on a side surface of the suction unit 120. The sensing range of a physical collision with an obstacle can be increased.

Referring back to FIG. 2, the side bumper switches 122 b and 122 c may protrude further than both the sides of the cleaner body 110 in a side direction. In other words, the width of the cleaner head with bumper switches is wider than the width of the cleaner body. When an obstacle is located on a side surface of the robot cleaner 100, the side bumper switch 122 b or 122 c collides with the obstacle earlier than the cleaner body 110, so that the obstacle can be effectively sensed.

The bumper switch 122 includes a bumper 122′ and a switch 122″. The bumper 122′ is a part mounted to the case 121 to be exposed to the outside and movable inwards, and the bumper 122′ is pressurized when it is in contact with an obstacle.

An elastic member or elastic spring pressurizes the bumper 122′ to the outside. The elastic spring may be provided at the inside of the bumper 122′ so that the bumper 122′ returns to the original state when the bumper 122′ is pressurized by the obstacle. The elastic member may be supported by the bumper 122′ and the case 121. The switch 122″ is provided at the inside of the bumper 122′ to generate an electrical signal by being pressurized when the bumper 122′ is moved inward. A micro-switch may be used as the switch 122″.

If a contact signal with an obstacle is transmitted through the bumper switch 122, the controller determines that the suction unit 120 has collided with the obstacle to control the driving of the wheel unit 111. For example, the controller may apply a driving force in the opposite direction to the main wheels 111 a such that the robot cleaner 100 moves rearward. Alternatively, the controller may apply a driving force to only any one of the main wheels 111 a or apply a driving force in different directions to both the main wheels 111 a such that the robot cleaner 100 rotates.

In the above, the bumper switch 122 is configured to be divided into the front bumper switch 122 a and the side bumper switches 122 b and 122 c, but the present disclosure is not limited thereto. The bumper switch 122 may be also formed in a ‘

’ shape to cover the front and left and right surfaces of the case 121. In such a case, the bumper switch 122 is configured to be movable to a rear side (when a portion provided at the front surface of the case 121 is in contact with an obstacle), a right side (when a portion provided at the left surface of the case 121 is in contact with an obstacle), and a left side (when a portion provided at the right surface of the case 121 is in contact with an obstacle).

As described above, when a mechanical bumper switch 122 is provided in the suction unit 120, a collision with an obstacle may be directly sensed as compared with when an electronic sensor (e.g., an acceleration sensor, a PSD sensor, etc.) is provided. Further, manufacturing cost can be reduced, and a circuit configuration can be simplified. In addition, an improved function of sensing an obstacle and changing a direction can be implemented by the combination of the bumper switch 122 and the sensing unit 130 provided to the cleaner body 110.

Meanwhile, when the robot cleaner is located close to a step, cliff, or a surface having a steep profile, an additional avoidance operation may be required. If an additional sensing of such a situation and control corresponding to the sensing are not provided, the robot cleaner may break after falling from the step, or may be unable to recover to climb or drive over the steep surface to perform cleaning again. To this end, the cliff sensor 124 that senses topography thereunder is provided at a front end portion of a lower side of the suction unit 120.

The cliff sensor 124 may be provided with a light emitting part (light emitter) and a light receiving part (light receiver), and measures a distance between the cliff sensor 124 and a floor G by measuring a time for which a beam irradiated onto the floor G from the light emitting part is received to the light receiving part. When a rapidly lowered surface exists at the front, the received time increases rapidly. When a cliff or step exists at the front, the emitted beam is not received by the light receiving part.

In these figures, it is illustrated that an inclined part 120 a upwardly inclined with respect to the floor G is formed at the front end portion of the lower side of the suction unit 120, and the cliff sensor 124 is installed at the inclined part 120 a to face the floor G. According to the above-described structure, the cliff sensor 124 is provided inclined toward the floor G at a front lower side of the suction unit 120. Therefore, topography the front lower side of the suction unit 120 may be sensed by the cliff sensor 124. Alternatively, the cliff sensor 124 may be provided parallel to the floor G to sense topography immediately under the cliff sensor 124.

If it is sensed through the cliff sensor that the topography under the cliff sensor is lowered to a certain level or lower, the controller controls the driving of the wheel unit 111. For example, the controller may apply a driving force in the opposite direction to the main wheels 111 a such that the robot cleaner 100 moves rearward in the reverse direction R. Alternatively, the controller may apply a driving force to only any one of the main wheels 111 a or apply a driving force in different directions to both the main wheels 111 a such that the robot cleaner 100 rotates.

The cliff sensor 124 may also be provided at the bottom surface of the cleaner body 110. By considering the function of the cliff sensor 124, a cliff sensor provided to the cleaner body 110 may be provided adjacent to the rear of the cleaner body 110.

For reference, as the inclined part 120 a is formed at the front end portion of the lower side of the suction unit 120, the robot cleaner 100 can easily climb a low threshold or obstacle. In addition, as shown in these figures, when an auxiliary wheel 123 is provided at the inclined part 120 a, the climbing may be more easily performed. For reference, the auxiliary wheel 123 is omitted in FIG. 14 so as to describe the cliff sensor 124.

Because the robot cleaner 100 is autonomously driven, it is required to charge the battery 180 provided in the cleaner body 110 to continuously use the robot cleaner 100. In order to charge the battery 180, a charging station as a power supply is provided, and a charging terminal 125 configured to be connectable to the charging station is provided in the suction unit 120. In these figures, it is illustrated that the charging terminal 125 is provided at the inclined part 120 a to be exposed to the front. The charging terminal 125 may be provided between the cliff sensors 124 which are provided at both sides of the suction unit 120.

Meanwhile, a brush roller 126 may be provided in the suction unit 120 to permit effective suction of dust. The brush roller 126 is rotatable in the inlet port 120 b′ to sweep foreign substances, e.g., dust and allow the dust to be introduced into the suction unit 120.

By considering the function of the brush roller 126, foreign substances may become stuck to the brush roller 126 over a length of time. Although there are needs for cleaning of the brush roller 126, the suction unit 120 typically has a structure making it difficult to disassemble the suction unit 120, resulting in difficulty to clean the brush roller 126. In the present disclosure, the brush roller 126 can be separated and cleaned easily without entire disassembly of the suction unit 120.

Referring to FIG. 17, the case 121 includes a main case 121 a and a cover case 121 b (or inner case). The main case 121 a is provided with the rotatable brush roller 126, and an opening 121 a′ is formed at one side of the main case 121 a. The front bumper switch 122 a is mounted at a front side of the main case 121 a, and any one of the side bumper switches 122 b and 122 c is mounted at the other side of the main case 121 a.

The cover case 121 b is detachably coupled to the main case 121 a to open/close the opening 121 a′ provided at the one side of the main case 121 a. The other of the side bumper switches 122 b and 122 c is mounted to the cover case 121 b. If the cover case 121 b is separated from the main case 121 a, the opening 121 a′ provided at the one side of the main case 121 a is exposed to the outside. The brush roller 126 provided in the main case 121 a may be exposed to the outside through the opening 121 a′.

The manipulation part 127 (lock/unlock switch) through which locking of the cover case part 121 b to the main case part 121 a is released in manipulation thereof may be provided in the suction unit 120. The manipulation part 127 may be implemented in various types such as a slide type and a press type. In this embodiment, the manipulation part 127 of the slide type is installed at the main case part 121 a. An elastic member or elastic spring 128 elastically pressurizes the brush roller 126 inside the other side of the main case 121. A leaf spring, a coil spring, and the like may be used as the elastic member 128.

When the elastic member 128 is pressurized, the brush roller 126 held by the cover case 121 b is fastened to the main case 121 a. If the fastening is released by the manipulation of the manipulation part 127.

Referring to FIG. 18, air introduced into the suction unit 120 through the inlet port 120 b′ of the suction unit 120 is introduced into the cleaner body 110 through the communication part 120 b″. The air introduced into the cleaner body 120 is introduced into the dust container 140. The intake flow path corresponds to a flow path continued from the introduction port 110′ communicating with the communication part 120 b″ to the first opening 110 a (see FIG. 19). The intake flow path may be formed as a duct, a peripheral component(s), or a combination of the duct and the peripheral component(s). As illustrated, an intake duct 117 connects the introduction port 110′ to the first opening 110 a, thereby forming the inhalation flow path.

The communication part 120 b″ of the suction unit 120 may be provided under a bottom surface of the front side of the cleaner body 110. In this case, the introduction port 110′ is formed in the bottom surface of the front side of the cleaner body 110. In addition, as the dust container 140 is provided at the rear of the cleaner body 110, a fan motor module 170 and the battery 180 are provided at both left and right sides of the front of the dust container 140, respectively.

A front end portion of the inlet duct 117 communicating with the introduction port 110′ (inlet port) is formed to extend upward. In addition, the inlet duct 117 extends to one side of the cleaner body 110 while avoiding the battery 180. In this case, the inlet duct 117 may be provided to pass over the fan motor module 170 provided at the one side of the cleaner body 110.

The first opening 110 a is formed in an upper inner circumferential surface of the dust container accommodation part 113 to communicate with the entrance 140 a formed in an upper outer circumferential surface of the container 140. The inlet duct 117 is formed to extend upward toward the first opening 110 a from the introduction port 110′.

Air introduced into the dust container 140 passes through at least one cyclone in the dust container 140. Foreign substances, e.g., dust contained in the air is separated by the at least one cyclone and collected in the dust container 140. The air having the foreign substances removed therefrom is discharged from the dust container 140.

Air forms a rotational flow in the dust container 140, and foreign substances and air are separated from each other by a difference in centrifugal force between the air and the dust. The air is flowed into the exit 140 via the at least one cyclone by a suction force generated by the fan motor module 170. Since an inertial force caused by the weight of the foreign substance is larger than the suction force generated by the fan motor module 170, the foreign substances are collected at a lower portion of the dust container 140 by gradually falling into the dust container 140.

The introduction port 110′ may be formed at the bottom center surface of the front side of the cleaner body 110. The entrance 140 a of the dust container 140 may be formed opened in a tangential direction in an inner circumferential surface of the dust container 140 such that air is introduced in a lateral direction to naturally form a rotational flow. In the state in which the dust container 140 is accommodated in the dust container accommodation part 113, the entrance 140 a may be located in a lateral direction of the cleaner body 110.

The air having the dust separated therefrom is discharged or exhausted from the dust container 140 and then is finally discharged to the outside through the exhaust port 112 via the exhaust port in the cleaner body 110. The exhaust flow path corresponds to a flow path from the second opening 110 b (see FIG. 19) to the exhaust port 112. The exhaust flow path may be formed as a duct, a peripheral component(s), or a combination of the duct and the peripheral component(s).

The exhaust flow path is configured as a combination of an exhaust duct 118 that connects the second opening 110 b to the fan exhaust port of the fan motor module 170 and an internal component(s) that guides the flow of air from the fan exhaust port 170 to the exhaust port 112. The fan exhaust port may be provided adjacent to a central portion of the cleaner body 110 to reduce noise discharged to the outside. Correspondingly, the second opening 110 b may also be formed adjacent to the central portion of the cleaner body 110.

A front end portion of the exhaust duct 118 communicating with the second opening 110 b and a rear end portion of the intake port 117 communicating with the first opening 110 a may be provided side by side at the same height.

Referring to FIG. 19, the dust container accommodation part 113 (dust container dock) to dock the dust container 140 therein is formed in the cleaner body 110. The dust container accommodation part 113 has a shape indented toward a front side from a rear side of the cleaner body 110, and is opened rearward and upward. The dust container accommodation part 113 may be defined by a bottom surface supporting the dust container 140 and an inner wall surrounding a portion of the outer circumference of the dust container 140.

A recessed part 116 (recess) dented from the top surface of the cleaner body 110 is formed along the outer circumference of the dust container accommodation part 113. The dust container cover 150 is provided for in the dust container accommodation part 113 and rotatably hinged. The dust container cover 150 is provided to simultaneously cover the top surface of the dust container 140 and the recessed part 116 (see FIG. 2). A portion of the dust container cover 150 is accommodated in the recessed part 116 in the state in which the dust container cover 150 is coupled to the dust container 140.

The first opening 110 a and the second opening 110 b are formed in the inner wall of the dust container accommodation part 113. The first opening 110 a and the second opening 110 b may be provided at the same height. As illustrated, the first opening 110 a and the second opening 110 b are laterally formed adjacent to each other at an upper end of the inner wall of the dust container accommodation part 113.

In order to form the flow of air continued from the intake flow path to the exhaust flow path through the dust container 140, the first and second openings 110 a and 110 b are to be provided to respectively communicate with the entrance 140 a and the exit 140 b. In order to permit the communication, the dust container 140 is to be mounted at a normal position of the dust container accommodation part 113.

A mounting or alignment projection 113 b is formed to protrude from the bottom surface of the dust container accommodation part 113, and a mounting or alignment groove 149 (see FIG. 22) corresponding to the mounting projection 113 b is formed in a bottom surface of the dust container 140. The dust container 140 may be mounted at the normal position of the dust container accommodation part 113 as the mounting projection 113 b is accommodated in the mounting groove 149.

The mounting projection 113 b may be formed at a position such that the dust container 140 shaped cylindrically is not rotated when docked in the dust container accommodation part 113. For example, the mounting projection 113 b may be formed at both left and right sides with respect to the center of the dust container 140.

The positions of the mounting projection 113 b and the mounting groove 149 may be reversed to each other. The mounting projection may be formed to protrude from the bottom surface of the dust container 140, and the mounting groove may be formed in the bottom surface of the dust container accommodation part 113.

A protruding part or a protrusion 113 a may be formed to protrude from the bottom surface of the dust container accommodation part 113, and a groove part or a recess 148 (see FIG. 22) corresponding to the protruding part 113 a may be formed in the bottom surface of the dust container 140. The groove part 148 may be formed at the center of the dust container 140.

The dust container accommodation part 113 or the dust container 140 may be provided with gaskets 110 a′ and 110 b′ that maintain airtightness between the first opening 110 a and the entrance 140 a and airtightness between the second opening 110 b and the exit 140 b when the dust container 140 is mounted at the normal position of the dust container accommodation part 113. The gaskets 110 a′ and 110 b′ may be formed to surround the first opening 110 a and the second opening 110 b, or be formed to surround the entrance 140 a and the exit 140 b.

As illustrated in FIGS. 20 and 21, the dust container 140 is accommodated in the dust container accommodation part 113 formed at the other side of the cleaner body 110, and is configured to collect dust filtered from sucked air. The dust container 140 may be formed in a cylindrical shape, and include an external case 141 a defining appearance, an upper case 141 b, an upper cover 141 d, and a lower case 141 c.

The external case 141 a is formed in a cylindrical shape with both ends open so as to define a side appearance of the dust container 140. The dust container 140 is provided with the entrance 140 a through which unfiltered air is introduced, and the exit 140 b through which filtered air is discharged. The entrance 140 a and the exit 140 b may be formed through a side surface of the external case 141 a. The entrance 140 a and the exit 140 b may be arranged at the same height. The entrance 140 a and the exit 140 b may be formed adjacent to each other at an upper end of the external case 141 a.

At least one cyclone may be provided in the external case 141 a. For example, a first cyclone 147 a filtering larger substances and/or particles from air introduced through the entrance 140 a and a second cyclone 147 b provided in the first cyclone 147 a to filter fine substance and/or particles may be provided in the external case 141 a.

The unfiltered air, introduced into the dust container 140 through the entrance 140 a flows along the first cyclone 147 a as an empty space which is formed in an annular shape between the external case 141 a and the inner case 141 h. During the flow, relatively heavy particles (e.g., debris and/or dust) is dropped down and collected and relatively light air is introduced into the inner case 141 h through a mesh filter 141 h′ by a suction force. Finer particles (e.g., fine dust and/or ultrafine dust) may be introduced into the inner case 141 h together with the air.

The mesh filter 141 h′ is mounted in the inner case 141 h to spatially partition inside and outside of the inner case 141 h. The mesh filter 141 h′ is formed in a mesh shape or a porous shape such that the air can flow therethrough.

A criterion for distinguishing sizes of dust and fine dust may be decided by the mesh filter 141 h′. Foreign substances and/or particles as small as passing through the mesh filter 141 h′ may be classified as the fine dust, and foreign substances and/or particles failing to pass through the mesh filter 141 h′ may be classified as the dust.

Foreign materials and dust which have dropped down without passing through the mesh filter 141 h′ are collected in a first storage portion or chamber S1 located under the mesh filter 141 h′. The first storage portion S1 is defined by the external case 141, the inner case 141 h and the lower case 141 c.

A skirt 141 h 1 may be provided at a lower side of the mesh filter 141 h′ protruding along a circumference of the inner case 141 h. The skirt 141 h 1 may restrict air flow into the first storage portion Si located under the skirt 141 h 1. This may result in preventing the foreign materials and dust collected in the first storage portion Si from being dispersed and upward reverse flow toward the skirt 141 h 1.

The second cyclone 147 b is configured to separate fine dust from the air introduced therein through the mesh filter 141 h′. The second cyclone 147 b includes a cylindrical portion and a conical portion extending downwardly from the cylindrical portion. In the cylindrical portion, the air rotates due to a guide vane provided in therein. In the conical portion, the fine dust and the air are separated from each other, and the second cyclone 147 b may be provided in plurality. The second cyclones 147 b may be arranged within the first cyclone 147 a in an up and down direction of the dust container 140. The height of the dust container 140 may be reduced with respect to the arrangement structure of the second cyclones on the first cyclone.

The air introduced into the inner case 141 h is introduced into intake openings 147 b′ on upper portions of the second cyclones 147 b. An empty space in which the second cyclones 147 b are not arranged within the inner case 147 h is used as a path along which the air flows upward. The empty space may be formed by the adjacent cyclones 147 b and/or by the inner case 141 h and the second cyclones 147 b adjacent to the inner case 141 h.

A vortex finder 147 b 1 through which air from which the fine dust is separated is discharged is provided on a center of the upper portion of each second cyclone 147 b. The intake opening 147 b′ may be defined as an annular space between an inner circumference of the second cyclone 147 b and an outer circumference of the vortex finder 147 b 1.

A guide vane extending in a spiral shape along an inner circumference is provided in the intake opening 147 b′ of the second cyclone 147 b. The guide vane allows air introduced in the second cyclone 147 b through the introduction opening 147 b′ to be rotated. The vortex finder 147 b 1 and the guide vane are arranged in the cylindrical portion of the second cyclone 147 b. Additional details may be found in U.S. application Ser. No. 15/487,756 (Attorney Docket No. P-1509), and U.S. application Ser. No. 15/487,821 (Attorney Docket No. P-1510), both filed on Apr. 14, 2017, whose entire disclosures are incorporated herein by reference.

The fine dust gradually flows downward while spirally orbiting along the inner circumference of the second cyclone 147 b, is discharged through a discharge opening 147 b″ and is finally collected in a second storage portion S2. The air which is relatively lighter than the fine dust is discharged through the upper vortex finder 147 b 1 by a suction force.

The second storage portion or chamber S2 may be called as a fine dust storage portion in the aspect of forming a storage space of the fine dust. The second storage portion S2 is a space defined by an inside of the inner case 141 h and the lower case 141 c.

A cover 141 k is arranged on the top of the second cyclones 147 b. The cover 141 k is provided to cover the intake openings 147 b′ of the second cyclones 147 b with a predetermined interval. The cover 141 k is provided with communication holes 141 k′ corresponding to the vortex finders 147 b 1. The cover 141 k may be provided to cover the inner case 141 h except for the vortex finders 147 b 1.

A partition plate 141 b 2 is installed on outer circumferences of the second cyclones 147 b. The partition plate 141 b 2 partitions a space such that the air introduced into the inner case 141 h through the mesh filter 141 h′ is not mixed with the fine dust discharged through the discharge opening 147 b″. The air passed through the mesh filter 141 h′ flows above the partition plate 141 b 2 and the fine dust discharged through the discharge opening 147 b″ is collected below the partition plate 141 b 2.

The discharge opening 147 b″ of the second cyclone 147 b has a shape penetrating through the partition plate 141 b 2. The partition plate 141 b 2 may be formed integral with the second cyclone 147 b, or may be mounted on the second cyclone 147 b after being produced as a separate member.

A flow separation member or guide 141 g is provided on an inner upper portion of the external case 141 a. The flow separation member 141 g separates a flow of air introduced through the entrance 140 a of the dust container 140 from a flow of air discharged through the exit 140 a of the dust container 140.

The upper case 141 b is provided to cover the flow separation member 141 g, and the lower case 141 c is provided to cover a lower portion of the external case 141 a. The flow separation member 141 g, the upper case 141 b, the upper cover 141 d and the filter 141 f will be described later.

Since the dust container 140 is configured to be detachably coupled to the dust container accommodation part 113, a handle 143 may be provided to the dust container 140 such that the dust container 140 may be grabbed for detachment from the dust container accommodation part 113. The handle 143 is hinge-coupled to the upper case 141 b to be rotatable. A handle accommodation part or recess 142 having the handle 143 accommodated therein is formed in the upper case 14 lb.

When the dust container cover 150 is coupled to the dust container 140 to cover the dust container 140, the handle 143 may be pressurized by the dust container cover 150 to be accommodated in the handle accommodation part 142. In a state in which the dust container cover 150 is separated from the dust container 140, the handle 143 may protrude from the handle accommodation part 142. To this end, the upper case 141 b may be provided with an elastic part or elastic spring that elastically pressurizes the handle 143.

A locking hook 145 may be formed to protrude from the upper case 141 b. The locking hook 145 is formed at the front of the upper case 141 b. The front of the upper case 141 b means a direction toward the front of the cleaner body 110 when the dust container 140 is mounted normally in the dust container accommodation part 113.

The locking hook 145 is accommodated in an accommodation or locking groove 116 a formed in the recessed part 116 of the cleaner body 110. The locking hook 145 may have a shape protruding from an outer circumferential surface of the upper case 141 b to be bent downward. A step 116 a′ is formed in the accommodation groove 116 a, and the locking hook 145 may be configured to be locked to the step 116 a′. See FIGS. 35-36.

FIG. 22 is a bottom view of the dust container 140 illustrated in FIG. 20. The lower case 141 c may be rotatably coupled to the external case 141 a by a hinge 141 c′. A lock 141 c″ provided to the lower case 141 c is detachably coupled to the external case 141 a, to allow the lower case 141 c to be fixed to the external case 141 a when the lock 141 c″ is coupled to the external case 141 and to allow the lower case 141 c to be rotatable with respect to the external case 141 a when the coupling is released.

The lower case 141 c is coupled to the external case 141 a to form a bottom surface of the first storage portion 51 and the second storage portion S2. When the lower case 141 c is rotated by a hinge portion 141 c′ to simultaneously open the first storage portion 51 and the second storage portion S2, the dust and the fine dust may simultaneously be discharged.

The hinge 141 c′ and the lock 141 c″ may be provided at positions opposite to each other with the center of the lower case 141 c, which is interposed therebetween. When the dust container 140 is normally mounted in the dust container accommodation part 113, the hinge part 141 c′ and the locking member 141 c″ may be covered by the inner wall of the dust container accommodation part 113 and not exposed to the outside.

The mounting groove 149 corresponding to the mounting projection 113 b is formed at a bottom surface of the lower case 141 c. As shown in FIG. 21, the mounting groove 149 may be formed at a position adjacent to the hinge part 141 c′ and the locking member 141 c″. The groove part 148 corresponding to the protruding part 113 a may be formed in the bottom surface of the lower case 141 c. The groove part 148 may be formed at the center of the dust container 140.

FIG. 23 is a view illustrating a state in which the dust container 140 is mounted in the dust container accommodation part 113 shown in FIG. 19. When the dust container 140 is not mounted in the dust container accommodation part 113, the dust container cover 150 may be provided upwardly inclined by a hinge 150 a that provide an upward elastic force. The dust container 140 may be inserted downwardly inclined at a rear upper side of the dust container accommodation part 113 for docketing in the dust container accommodation part 113.

If the dust container 140 is docked normally, the locking hook formed to protrude from the outer circumference of the dust container 140 is accommodated in the accommodation groove 116 a formed in the recessed part 116 of the cleaner body 110. The accommodation groove 116 a has a shape dented relatively further than the recessed part 116.

Accordingly, the step 116 a′ is formed in the accommodation groove 116 a. The step 116 a′ is inserted into the inside of the locking hook 145 to be locked when the locking hook 145 is moved in a lateral direction. In the state in which the dust container cover 150 is coupled to the dust container 140, the duct container cover 150 is provided to cover the locking hook 145. When the dust container 140 is accommodated in the dust container accommodation part 113, a top surface of the upper case 141 b of the dust container may be at the same plane as the recessed part 116.

An alignment mark 146 may be formed at an upper portion of the dust container 140, and a guide mark 116′ corresponding to the alignment mark 146 may be formed at the recessed part 116, so that the locking hook 145 can be accommodated at the regular position of the accommodation groove 116 a. The alignment mark 146 may be engraved or painted in the upper case 141 b and the guide mark 116′ may be engraved or painted in the recessed part 116.

The accommodation groove 116 a may be formed to extend long toward the front of the cleaner body 110. When the dust container cover 150 is coupled to the dust container 140, the hinge 150 a of the duct container cover 150 may be accommodated into the accommodation groove 116 a.

The locking hook 145 is locked to the step 116 a′ of the accommodation groove 116 a, so that the dust container 140 is restricted from being moved in the lateral direction in the dust container accommodation part 113. The mounting projection 113 b of the dust container accommodation part 113 is inserted into the mounting groove 149 formed in the dust container 140. The dust container 140 is also restricted from being moved in the lateral direction in the dust container accommodation part 113.

The dust container 140 may not separate from the dust container accommodation part 113 except when the dust container 140 is moved upward. When the dust container cover 150 is fastened to the dust container 140 to cover the dust container 140, the dust container 140 is also restricted from being moved upward. Thus, the dust container 140 cannot be separated from the dust container accommodation part 113.

Referring to FIGS. 24 to 30 in conjunction with FIG. 20, the upper cover 141 d is configured to open/close an upper opening 141 b′ of the dust container 140. The upper opening 141 b′ may be formed in the upper case 141 b, and the upper cover 141 d is detachably coupled to the upper case 141 b to open/close the upper opening 141 b′. The upper opening 141 b′ is provided to overlap with the cover 141 k. See FIG. 30.

The upper cover 141 d is provided with manipulation parts 141 d′ (lock/unlock mechanical switch) that allows the upper cover 141 d to be fastened to the upper case 141 b and allow the fastening to be released. The manipulation parts 141 d′ may be respectively formed at both left and right sides of the upper cover 141 d, to permit pressing in directions opposite to each other, i.e., inward and returning to the original state by an elastic force. See FIG. 29.

The upper cover 141 d is provided with fixing projections 141 d″ withdrawn or retracted from the outer circumference of the upper cover 141 d in linkage with the manipulation of the manipulation part 141 d. When the pressing manipulation of the manipulation parts 141 d′ is performed, the fixing projections 141 d″ are retracted into accommodation parts formed in the upper cover 141 d not to protrude from the outer circumference of the upper cover 141 d. If the manipulation parts 141 d′ are turned to the original state by the elastic force, the fixing projections 141 d″ protrude from the outer circumference of the upper cover 141 d.

A fixing groove 141 b″ having the fixing projection 141 d″ inserted and fixed thereinto is formed in an inner surface of the upper case 141 b, which forms the upper opening 141 b′. The fixing groove 141 b″ may be formed at a position corresponding to each of the fixing projections 141 d″, so that the fixing grooves 141 b″ are opposite to each other. The fixing groove 141 b″ may be formed in a loop shape to extend along the inner surface of the upper case 141 b to allow a greater degree of freedom in installing the fixing projections 141 d″.

The flow separation member or guide 141 g that separate the flow of the air introduced through the entrance 140 a from the flow of the air discharged toward the exit 140 a, and guides the air flow in the dust container 140. The flow separation member 141 g may be coupled to an upper end portion at an inner side of the external case 141 a.

First and second holes 141 a′ and 141 a″ corresponding to the entrance 140 a and the exit 140 b of the dust container 140 are formed through the external case 141 a. A first opening 141 g′ and a second opening 141 g″ corresponding to the first and second holes 141 a′ and 141 a″ are formed through the flow separation member 141 g. With this structure, when the flow separation member 141 g is coupled to the inner side of the external case 141 a, the first hole 141 a′ and the first opening 141 g′ communicate with each other to form the entrance 140 a of the dust container 140, and the second hole 141 a″ and the second opening 141 g″ communicate with each other to form the exit 140 b of the dust container 140. See FIG. 29.

The flow separation member 141 g may be provided with insertion protrusions 141 g 2 which are inserted into recesses 141 a 1 formed on an inner circumferential surface of the external case 141 a. A support rib 141 g 3 may protrude from an upper portion of the flow separation member 141 g along a circumference, such that the flow separation member 141 g can be supported on an upper end of the external case 141 a.

The flow separation member 141 g has a hollow portion and is provided with a flow separating part 141 g′ surrounding the hollow portion along a circumference. The hollow portion of the flow separation member 141 g is configured to overlap the cover 141 k such that air discharged through the communication holes 141 k′ can be introduced into an upper portion of the flow separating parts 141 g 1.

The first and second openings 141 g′ and 141 g″ are formed on surfaces of the flow separation member 141 g, which are opposite to each other. As shown in this figure, the first opening 141 g′ is provided on a bottom surface of the flow separation member 141 g, so that air introduced through the entrance 140 a flows at a lower portion of the flow separation member 141 g. The second opening 141 g″ is provided on a top surface of the flow separation member 141 g, so that air discharged toward the exit 140 b flows at an upper portion of the flow separation member 141 g.

The flow separation member 141 g is formed to block between the first opening 141 g′ and the second opening 141 g″, so that air introduced through the first opening 141 g′ and air discharged toward the second opening 141 g″ are separated from each other. The first opening 141 g′ may be provided with a guide part 141 g 4 which extends from one side of the first opening 141 g′ to guide air introduced into the dust container 140 to form a rotational flow. The exit 140 b of the dust container 140 may be formed to minimize flow loss and to harmonize with peripheral structures without interruption.

The first opening 141 g′ and the second opening 141 g″ may be laterally provided side by side along the circumference of an upper portion of the flow separation member 141 g. Accordingly, the entrance 140 a and the exit 140 b of the dust container 140 corresponding to the first and second openings 141 g′ and 141 g″, respectively, may be formed at the same height of the dust container 140. The entrance 140 a is formed at an upper portion of the dust container 140 such that air introduced into the dust container 140 does not scatter dust collected on the bottom of the dust container 140.

In a cleaner (e.g., an upright type cleaner, a canister type cleaner, etc.) in which the height of the multi-cyclone is less restricted, an exit is typically installed at a position higher than that of an entrance. However, in the robot cleaner 100 of the present disclosure, when the capacity of the dust container 140 is to increase while considering of height restriction, the exit 140 b along with the entrance 140 a may be formed at the same height of the dust container 140.

In the structure of the present disclosure, in which air introduced through the entrance 140 a is guided by the downwardly inclined flow separating part 141 g 1 (inclined guide), an angle at which the air introduced through the entrance 140 a flows downward is related to inclination of the flow separating part 141 g 1. In this respect, if the inclination of the flow separating part 141 g 1 is large, the air introduced through the entrance 140 a does not receive a sufficient centrifugal force, and may scatter dust collected on the bottom of the dust container 140.

The inclination of the flow separating part 141 g 1 may be relatively as small as possible. Since the flow separating part 141 g 1 is continued from an upper side of the entrance 140 a to a lower side of the exit 140 b, when the entrance 140 a and the exit 140 b are formed at the same height of the dust container 140, the downward inclination of the flow separating part 141 g 1 becomes more gentle as the length of the flow separating part 141 g 1 becomes longer. The flow separating part 141 g 1 is formed longest when the second opening 141 g″ is located immediately next to the first opening 141 g′.

As illustrated, the entrance 140 a and the exit 140 b are laterally formed side by side at an upper end of the external case 141 a. The flow separation member 141 g may have a shape downwardly inclined spirally along an inner circumferential surface of the external case 141 a from an upper end of the first opening 141 g′ to the lower end of the second opening 141 g″.

The inner case 141 h, the cover 141 k and the flow separation member 141 g are coupled together. The inner case 141 h may be provided with coupling bosses 141 h″ for coupling to the cover 141 k and the flow separation member 141 g.

The multi-cyclone provided within the dust container 140 filters foreign substances or dust in air introduced into the dust container 140 through the entrance 140 a. The air having the foreign substances or dust filtered therefrom ascends and flows toward the exit 140 b at an upper portion of the flow separating part 141 g 1. In the present disclosure, the dust container 140 has a structure in which foreign substances or dust is again filtered before the air flowing as described above is finally discharged through the exit 140 b.

A filter 141 f that passes through the multi-cyclone and then filters foreign substances or dust in air discharged toward the exit 140 b is provided at a rear surface of the upper cover 141 d. The filter 141 f is provided to cover the cover 141 k, so that dust in air passing through the vortex finder of the second cyclone 147 b can be filtered by the filter 141 f.

When the upper cover 141 d is mounted to the upper case 141 b, the filter 141 f is provided to cover the cover 141 k. For example, the filter 141 f may be adhered closely to the top surface of the flow separating part 141 g 1 or be adhered closely to a top surface of the cover 141 k.

The filter 141 f may be mounted to a mounting rib 141 e protruding from the rear surface of the upper cover 141 d. The mounting rib 141 e includes a plurality of protruding parts 141 e′ and a mounting part 141 e″. The mounting rib 141 e may be integrally formed with the upper cover 141 d in injection molding of the upper cover 141 d.

The protruding parts 141 e′ are formed to protrude from the rear surface of the upper cover 141 d, and are provided at a plurality of places, respectively. The mounting part 141 e″ is provided to be spaced apart from the rear surface of the upper cover 141 d at a certain distance, and is supported at a plurality of places by the plurality of protruding parts 141 e′. The mounting part 141 e″ may be formed in a loop shape larger than the hollow portion of the flow separation member 141 g.

The filter 141 f includes a filter part 141 f′ and a sealing part 141 f′. The filter part 141 f′ is provided to cover the hollow portion of the flow separation member 141 g or the cover 141 k to filter foreign substances or dust in air discharged through the communication holes 141 k of the cover 141 k. The filter part 141 f′ may have a mesh shape.

The sealing part 141 f′ is provided to surround the filter part 141 f′, and is mounted to the mounting part 141 e″ to allow the filter 141 f to be fixed to the mounting rib 141 e. In order for the filter 141 f to be fixed to the mounting rib 141 e, a groove into the mounting part 141 e″ is inserted may be formed in the sealing part 141 f′. The sealing part 141 f′ may be adhered closely to the top surface of the flow separating part 141 g 1 or the top surface of the cover 141 k to cover the communication holes 141 k′ of the cover 141 k.

Air from which foreign substances or dust is filtered by the multi-cyclone is discharged toward the exit 140 b through an empty space between the protruding parts 141 e′ by passing through the filter part 141 f′. Here, the empty space is formed at the outer circumference of the filter 141 f, and communicates with an upper portion of the flow separating part 141 g 1. In addition, the sealing part 141 f′ is configured to seal a gap between the filter 141 f and the top surface of the flow separating part 141 g 1 adhered closely to the filter 141 f or the top surface of the cover 141 k, so that it is possible to prevent foreign substances or dust in air from being discharged toward the exit 140 b through the gap.

Referring to FIGS. 31 and 32 in conjunction with FIGS. 1 to 3, the dust container cover 150 is rotatably coupled to the cleaner body 110 by a hinge 150 a, and is provided to completely cover a top surface of the dust container 140 when the dust container cover 150 is coupled to the dust container 140. In this state, a portion of the dust container cover 150 is accommodated in at the dust container accommodation part 113, and the other portion of the dust container cover 150 may be formed to protrude toward the rear of the cleaner body 110 (i.e., in the reverse direction R opposite to the forward direction F). The hinge 150 a is configured to elastically pressurize the dust container cover 150 in the upper direction. When the dust container cover 150 is not coupled to the dust container 140, the dust container cover 150 may be tilted upwardly inclined with respect to the top surface of the dust container 140.

The dust container cover 150 may be formed in an elliptical shape in the front-rear direction of the cleaner body 110 to completely cover the circular dust container 140 when the dust container cover 150 is coupled to the dust container 140. A recessed part 116 dented from the top surface of the cleaner body 110 is formed along the outer circumference of the dust container accommodation part 113 in the cleaner body 110 (see FIGS. 19 and 23). The dust container cover 150 is accommodated in the dust container accommodation part 113 through rotation thereof.

The dust container cover 150 is provided to simultaneously cover the top surface of the dust container and the recessed part 116. A front-rear length of the dust container cover 150 corresponding to the front-rear direction of the cleaner body 110 may be formed longer than a left-right length of the dust container cover 150 corresponding to the left-right direction of the cleaner body 110. The left-right direction is formed equal to or longer than a radius of the dust container cover 150.

The dust container cover 150 may be provided with at least one of a touch key 150′, a touch screen 150″, and a display. The touch screen 150″ may be distinguished from the display that outputs visual information but has no touch function, in that the touch screen 150″ outputs visual information and receives a touch input to the visual information. The dust container cover 150 may include a top cover 151, a bottom cover 152, and a middle frame 153 between the top cover 151 and the bottom cover 152. The components may be formed of a synthetic resin material.

The top cover 151 may be configured to have a certain degree of transparency. For example, the top cover may be translucent. Alternatively, the top cover itself may be formed to be transparent, and a film attached to a rear surface of the top cover 151 may be translucent. As the top cover 151 has the transparency, a pictogram of the touch key 150′ or visual information output from the touch screen 150″ or the display may be transmitted to a user through the top cover 151.

A touch sensor that senses a touch input to the top cover 151 may be attached to the rear surface of the top cover 151. The touch sensor may constitute a touch key module 154 a and/or a touch screen module 154 b, which will be described later.

The bottom cover 152 is coupled to the top cover 151, so that the top cover 151 and the bottom cover 152 form an appearance of the dust container cover 150. The bottom cover 152 may be formed of an opaque material, and form a mounting surface on which electronic devices or a sub-circuit board 151 can be mounted in the dust container cover 150.

The hinge 150 a rotatably coupled to the cleaner body 110 may be coupled to the top cover 151 or the bottom cover 152. The hinge part 150 a may be provided in the top cover 151 or the bottom cover 152.

The electronic devices or the sub-circuit board 157 may be mounted on the bottom cover 152. For example, the sub-circuit board 157 electrically connected to a main circuit board of the cleaner body 110 may be mounted on the bottom cover 152. The main circuit board may be configured as an example of the controller for operating various functions of the robot cleaner 100.

Various electronic devices are mounted on the sub-circuit board 157. In FIG. 23, the touch key module 154 a, the touch screen module 154 b, and infrared receiving units 156 (e.g., IR sensors) are electrically connected on the sub-circuit board 157. The electrical connection includes not only that the electronic devices are mounted on the sub-circuit board 157 but also that the electronic devices are connected to the sub-circuit board 157 through a flexible printed circuit board (FPCB).

A pictogram may be printed on the top cover above the touch key module 154 a, and the touch key module 154 a is configured to sense a touch input to the pictogram of the top cover 151. The touch key module 154 a may include a touch sensor, and the touch sensor may be provided to be attached or adjacent to the rear surface of the top cover 151. The touch key module 154 a may further include a backlight unit that lights the pictogram.

The touch screen module 154 b provides an output interface between the robot cleaner 100 and the user through the output of visual information. The touch screen module 154 b senses a touch input to the top cover 151 to provide an input interface between the robot cleaner 100 and the user. The touch screen module 154 b includes a display that outputs visual information through the top cover 151 and a touch sensor that senses a touch input to the top cover 151, and the display and the touch sensor form a mutual-layered structure or is integrally formed, thereby implementing a touch screen.

The touch screen module 154 b may be accommodated in a through-hole 153 b of the middle frame 153 to be coupled to the middle frame 153 through bonding, hook-coupling, or the like. In this case, the touch screen module 154 b may be electrically connected to the sub-circuit board 157 through the FPCB. The touch screen module 154 b may be attached to or provided adjacent to the rear surface of the top cover 151.

The dust container cover 150 may be provided with an acceleration sensor 155. The acceleration sensor 155 may be mounted on the sub-circuit board 157 or be electrically connected to the sub-circuit board 157 through the FPCB. The acceleration sensor 155 senses a gravitational acceleration acting on the acceleration sensor 155, which is divided into X, Y, and Z vectors perpendicular to one another.

The controller may sense whether the dust container cover 150 has been opened/closed, using X, Y, and Z vector values sensed by the acceleration sensor 155. Specifically, based on a state in which the dust container cover 150 is closed, at least two vector values are changed in a state in which the dust container cover 150 is opened (tilted). That is, the vector values sensed through the acceleration sensor 155 are changed depending on a degree to which the dust container cover 150 is inclined.

When a difference between vector values in the two states is equal to or greater than a preset reference value, the controller may determine that the dust container cover 150 has not been coupled to the dust container 140, to generate a corresponding control signal. For example, if the dust container cover 150 is in a tilted state as it is opened, the controller 155 may senses the tilted state to stop the driving of wheel unit 111 and generate an alarm.

In addition, if vibration is applied to the dust container cover 150, vector values sensed through the acceleration sensor 155 are changed. When a difference between the vector values, which is equal to or greater than the preset reference value, is sensed within a certain time, the state of the touch screen module 154 b may be changed from a non-activation (OFF) state to an activation (ON) state. For example, if the user taps the dust container cover 150 plural times in a state in which the touch screen module 154 b is not activated, the controller may sense the tapping of the user through the acceleration sensor 155 to change the state of the touch screen module 154 b from the non-activation state to the active state.

A gyro sensor may be used instead of the acceleration sensor 155. The acceleration sensor 155 and the gyro sensor may be used together, so that improved sensing performance can be implemented through complementary detection.

The infrared receiving units 156 may be provided at corner portions of the sub-circuit board 157 to receive infrared signals transmitted from directions different from one another. Here, the infrared signal may be a signal output from a remote controller (not shown) for controlling the robot cleaner 100 in manipulation of the remote controller.

The middle frame 153 is provided to cover the sub-circuit board 157, and has through-holes 153 a and 153 b respectively corresponding to the touch key module 154 a and the touch screen module 154 b, which are mounted on the sub-circuit board 157. Inner surfaces defining the through-holes 153 a and 153 b are formed to surround the touch key module 154 a and a touch screen module 154 b, respectively.

An accommodation part 153 c that is provided to cover an upper portion of each of the infrared receiving units 156 and has an opened front to receive infrared light may be provided at each corner portion of the middle frame 153. According to the above-described disposal, the infrared receiving unit 156 is provided to face a side surface of the dust container cover 150 (specifically, a side surface of the top cover 151 having transparency). Since the upper portion of the infrared receiving unit 156 is covered by the accommodation part 153 c, it is possible to prevent a malfunction of the infrared receiving unit 156, caused by a three-wavelength lamp provided on a ceiling or sunlight.

At least one portion of the dust container cover 150 may be provided to protrude further than the top surface of the cleaner body 110. As shown in these figure, the top cover 151 may be provided with a tapered part 151 a extending downwardly inclined to the outside from a top surface thereof. The tapered part 151 a may be formed to extend along the outer circumference of the top cover 151, and be located to protrude further than the top surface of the cleaner body 110 in the state in which the dust container cover 150 is coupled to the dust container 140 as shown in FIG. 3.

If a side surface vertically downwardly extending from the top surface of the top cover 151 is continuously formed, an infrared signal introduced into the top cover 151 at a corner portion of the top cover 151 is refracted or reflected, and therefore, the receiving performance of the infrared receiving unit 156 may be deteriorated. Further, if the side surface of the top cover 151 is completely covered by the top surface of the cleaner body 110, the receiving performance of the infrared receiving unit 156 may further deteriorate.

An infrared signal introduced into the top cover 151 can be introduced into the infrared receiving unit 156 provided adjacent to the inside of the tapered part 151 a without being almost refracted or reflected by the tapered part 151 a. In addition, as the tapered part 151 a is located to protrude further than the top surface of the cleaner body 110, and the infrared receiving unit 156 is provided in plural numbers to be spaced apart from each other at a certain distance inside the tapered part 151 a, infrared signals can be received in all directions. Thus, the receiving performance of the infrared receiving unit 156 may be improved.

Referring to FIGS. 33 and 34 in conjunction with FIG. 20, the dust container cover 150 is provided with the hook 158 configured to be fastened to a locking part 144 of the dust container 140. In these figures, it is illustrated that the hook part 158 is formed to protrude at one side of the bottom surface of the bottom cover 152. The hook part 158 may be provided at the opposite side of the hinge 150 a.

When the hook 158 is fastened to the locking part 144, the handle 143 provided at an upper portion of the dust container 140 is pressurized by the dust container cover 150 to be accommodated in the handle accommodation part 142. If the fastening between the hook part 158 and the locking part 144 is released, the handle 143 is pressurized by the elastic member to protrude from the handle accommodation part 142. As described above, the handle 143 may be provided inclined with respect to the upper case 141 b.

The locking part 144 provided in the dust container 140 includes a button part 144 a and a holding part 144 b. The locking part 144 is exposed to the rear of the cleaner body 110.

The button part 144 a is provided at a side surface of the dust container 140 to permit pressing manipulation, and the holding part 146 b is configured such that the hook part 158 of the dust container cover 150 can be locked thereto. Also, the holding part 146 b is configured such that the locking of the holding part 146 b to the hook part 158 is released in the pressing manipulation of the button part 144 a. The holding part 144 b may be formed at an upper portion of the dust container 140.

In the above, the case where the hook part 158 is provided in the dust container cover 150 and the locking part 144 is provided in the dust container 140 has been described as an example, but formation positions of the hook part 158 and the locking part 144 may be changed from each other. In other words, the locking part may be provided in the dust container cover 150 and the hook part may be provided in the dust container 140.

As described above, the dust container cover 150 is detachably coupled to the dust container by the fastening structure between the hook part 158 and the locking part 144. That is, there exists no direct fastening relation between the dust container cover 150 and the cleaner body 110, and the dust container cover 150 is fastened to the dust container 140 accommodated in the dust container accommodation part 113.

As described above, the dust container 140 accommodated in the dust container accommodation part 113 is restricted from being moved in the lateral direction by the fastening between the mounting projection 113 b and the mounting groove 149 and the fastening between the locking hook 145 and the step 116 a′. In the state in which the dust container 140 is accommodated in the dust container accommodation part 113, if the dust container cover 150 is fastened to the dust container 140 in a state in which the dust container cover 150 covers the dust container 140, the dust container 140 is also restricted from being moved upward. Thus, the dust container 140 can be prevented from being separated from the dust container accommodation part 113.

When the dust container 140 is not mounted, the dust container cover 150 is in a state in which it is freely rotatable about the hinge part 150 a, i.e., a non-fixing state. As described above, the dust container cover 150 may be provided upwardly tilted in the non-fixing state.

The dust container cover 150 is provided in a horizontal state when the dust container cover 150 is fastened to the dust container 140. If the dust container cover 150 is not fastened to the dust container 140, the dust container cover 150 is in a state in which it is tilted upwardly inclined. When the dust container 140 is not accommodated in the dust container accommodation part 113, the dust container cover 150 is also in the state in which it is tilted upwardly inclined. Thus, the user can intuitively check whether the dust container cover 150 has been fasted to the dust container 140, by checking, with the naked eye, whether the dust container cover 150 is in the state in which it is tilted.

Air filtered in the dust container 140 is discharged from the dust container and finally discharged to the outside through the exhaust port 112. A filter unit 160 that filters fine dust included in the filtered air is provided at the front of the exhaust port 112.

Referring to FIGS. 35 to 37, the filter unit 160 is accommodated in the cleaner body 110, and is provided at the front of the exhaust port 112. The filter unit 160 is exposed to the outside when the dust container 140 is separated from the dust container accommodation part 113. The exhaust port 112 may be formed in an inner wall of the cleaner body 110 that defines the dust container accommodation part 113. The exhaust port 112 may be formed at one (left or right) end portion of the cleaner body 110 that surrounds the dust container accommodation part 113. In this exemplary embodiment, it is illustrated that the exhaust port 112 is formed long along the height direction of the cleaner body 110 at the left end portion of the dust container accommodation part 113 on the drawing.

Air discharged from the second opening 110 b is guided to the exhaust port 112 through the exhaust flow path. In the structure in which the exhaust port 112 is formed at the one end portion of the cleaner body 110, the exhaust flow path extends to the one end of the cleaner body 100. The filter unit 160 is provided on the exhaust flow path.

The filter unit 160 includes a filter case 161 and a filter 162. The filter case 161 is provided with a hinge part 161 c hinge-coupled to the inner wall of the cleaner body 110 that defines the dust container accommodation part 113. The filter case 161 is configured to be rotatable with respect to the cleaner body 110.

The filter case 161 includes a filter accommodation part 161 a (filter housing) and a ventilation port 161 b that communicates with the filter accommodation part 161 a and is provided to face the exhaust port 112. Air introduced into the filter case 161 is discharged to the ventilation port 161 b via the filter 162 mounted in the filter accommodation part 161 a.

The filter 162 is mounted in the filter accommodation part 161 a. A HEPA filter for filtering fine dust may be used as the filter 162. A handle 162 a may be provided to the filter 162.

In FIG. 30, it is illustrated that the filter accommodation part 161 a is formed at a front surface of the filter case 161, and the ventilation port 161 b is formed in a side surface of the filter case 161. More specifically, a through-hole 161 e is formed in the side surface of the filter case 161, and a guide rail 161 f protrudes along the insertion direction of the filter 162 on a bottom surface of the filter case 161 to guide the insertion of the filter 162 through the through-hole 161 e.

The structure in which the filter 162 is mounted in the filter case 161 is not limited thereto. As another example, unlike the structure shown in FIG. 30, the filter 162 may be mounted at a front surface of the filter case 161 to be accommodated in the filter accommodation part 161 a. In this case, the filter 162 may be fixed to the filter accommodation part 161 a through hook coupling.

The filter case 161 may be received in the cleaner body 110 through an opening 115 formed in the inner wall of the cleaner body 110, and an outer surface of the filter case 161 is exposed to the outside in the state in which the filter case 161 is received in the cleaner body 110 to define the dust container accommodation part 113 together with the inner wall of the cleaner body 110. To this end, the outer surface of the filter case 161 may have a rounded shape, and be preferably formed as a curved surface having the substantially same curvature as the inner wall of the dust container accommodation part 113.

A knob 161 d may be formed on one surface of the filter case 161 that defines the dust container accommodation part 113 together with the inner wall of the cleaner body 110. Referring to FIGS. 2 and 19, when the dust container 140 is accommodated in the dust container accommodation part 113, the dust container 140 is configured to cover the filter case 161, and the knob 161 d is not exposed to the outside as the dust container 140 covers the knob 161 d.

The filter case 161 may be provided in the dust container accommodation part 113 in a state in which the filter case 161 is rotated to open the opening 115. The filter accommodation part 161 a is exposed to the outside, so that the filter 162 can be easily replaced.

Therefore, an aspect of the detailed description is to provide a new sensing unit capable of minimizing a sensing part, implementing a front monitoring/photographing function, a simultaneously localization and mapping function, and an obstacle sensing function, and improving obstacle sensing performance.

Another aspect of the detailed description is to provide a suction unit capable of more directly sensing a collision with an obstacle by complementing the sensing unit, and sensing in advance a step or cliff that is rapidly lowered when the step or cliff exist at the front thereof.

Still another aspect of the detailed description is to provide a structure in which a dust container can be firmly fixed to a dust container accommodation part, and assembly convenience of a cleaner body, a dust container, and a dust container cover can be improved.

Still another aspect of the detailed description is to provide a new flow structure in a dust container, which can increase the capacity of the dust container while considering a limitation of the height of a cleaner body.

Still another aspect of the detailed description is to provide a structure in which a filter for filtering fine dust can be easily replaced.

A robot cleaner according to the present disclosure may include a cleaner body including a plurality of wheels and a controller controlling driving of at least one of the wheels; a cleaner head protruding from the cleaner body, the cleaner head having an intake port to suction air containing foreign substances; and a sensor assembly mounted to the front of the cleaner body, wherein the sensor assembly protrude over top and side surfaces of the cleaner body, and an upper end of the sensor assembly protrude beyond the top surface of the cleaner body.

At least one portion of the sensor assembly vertically overlaps with the cleaner head protruding from the front of the cleaner body. The sensor assembly includes: a sensor oriented in an inclined angle relative to side and top surfaces at an upper corner of the cleaner body to capture an image of a front space and an upper space, which are in front of the cleaner body; a sensor module adjacent to the side surface of the cleaner body to sense an obstacle in front of the cleaner body or sense a vertical drop in front of the cleaner body; a window to cover the sensor and the sensor module, the window having a prescribe amount of transparency; and a case accommodating at least one portion of the window, the case being mounted in the cleaner body.

The case includes: a mounting frame having the sensor and the sensor module mounted therein; and a cover frame coupled to the mounting frame, the cover frame being mounted to cover the top and side surfaces of the cleaner body when at least one portion of the window is accommodated therein. An upper end of the cover frame is located above the sensor and protrudes beyond the top surface of the cleaner body.

The present disclosure has advantageous effects as follows.

First, the first sensing part is provided inclined with respect to one surface of the cleaner body to simultaneously photograph front and upper parts, and the controller divides a photographed image into front and upper images according to objects different from each other. Thus, the first sensing part can be more efficiently used, and the existing sensing parts provided for every object can be integrated as one.

Also, the second sensing part of the sensing unit includes the first and second pattern irradiating parts that respectively irradiate beams having first and second patterns toward a front lower side and a front upper side, and the image acquisition part that photographs the beams having the first and second patterns, so that a front geographic feature and an upper obstacle can be sensed together. As a result, the obstacle avoidance performance of the robot cleaner can be improved.

In addition, the first sensing part and the second sensing part are integrated to constitute one module called as the sensing unit, so that it is possible to provide a robot cleaner having a new form factor.

Second, the bumper switch that mechanically operates is provided in the suction unit provided to protrude from one side of the cleaner body, so that, when the suction unit collides with an obstacle, the collision can be directly sensed. In addition, side bumper switches respectively provided at both sides of the suction unit are provided to protrude in a lateral direction instead of both sides of the cleaner body, so that the collision with an obstacle in the lateral direction can be effectively sensed.

If the bumper switches are combined with the sensing unit, more improved obstacle sensing and a direction changing function corresponding thereto can be realized.

In addition, the cliff sensor is mounted at the inclined part of the suction unit, so that when a step or cliff that is rapidly lowered exists at the front, a proper avoidance operation can be performed by sensing the step or cliff in advance.

Also, the cover case part of the suction unit is configured to open/close the opening of the main case part, so that the brush roller built in the main case part can be withdrawn to the outside. Thus, the brush roller can be more easily cleaned.

Third, the dust container is restricted from being moved rearward by the locking structure between the dust container and the dust container accommodation part in a state in which the dust container is mounted in the dust container accommodation part, and is restricted from being moved upward in a state in which the dust container cover is fastened to the dust container. Thus, the dust container can be firmly fixed to the dust container accommodation part, and assembly convenience of the cleaner body, the dust container, and the dust container cover can be improved.

In addition, the accommodation part that is provided to cover an upper portion of each of the infrared receiving units and has an opened front to receive infrared light is provided in the middle frame of the dust container cover, so that it is possible to prevent a malfunction of the infrared receiving unit, caused by a three-wavelength lamp provided on a ceiling or sunlight. In addition, the side surface of the dust container cover is provided to protrude further than the top surface of the cleaner body, so that the receiving performance of the infrared receiving unit can be improved.

Fourth, the exit of the dust container is formed at the same height as the entrance of the dust container, so that the capacity of the dust container can be increased without increasing the height of the cleaner body. In addition, as the exit of the dust container is formed immediately next to the entrance of the dust container, the downward inclination angle of the guide part that separates the flow of air introduced into the entrance from the flow of air discharged toward the exit to be respectively guided to lower and upper portions thereof is decreased. Thus, air introduced through the entrance can form a sufficient rotational flow, and dust collected on the bottom of the dust container can be prevented from being scattered.

Fifth, the filter case is hinge-coupled to the cleaner body to open/close the opening formed in the inner wall of the dust container accommodation part. Thus, the filter case is provided in the dust container accommodation part in a state in which the filter case is rotated to open the opening, and the filter accommodation part is exposed to the outside, so that the filter can be easily replaced.

Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.

Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. 

What is claimed is:
 1. A robot cleaner comprising: a cleaner body including a plurality wheels and a controller controlling driving of at least one wheel; a cleaner head protruding from a front of the cleaner body, the cleaner head having an intake port to suction air containing foreign substances; and a sensor assembly attached to the front of the cleaner body, wherein at least one portion of the sensor assembly vertically overlaps with the cleaner head protruding from the front the cleaner body.
 2. The robot cleaner of claim 1, wherein the sensor assembly protrudes from top and side surfaces of the cleaner body.
 3. The robot cleaner of claim 1, wherein the sensing unit includes: a sensor being oriented in an inclined angle relative to the side and top surfaces at an upper corner portion of the cleaner body to capture an image of a front space and an upper space, which are in front of the cleaner body; and a sensor module adjacent to the side surface of the cleaner body to sense an obstacle in front of the cleaner body or sense a vertical drop located in front of the cleaner body.
 4. The robot cleaner of claim 3, wherein the sensor module includes: a first laser emitting a first laser beam toward a lower front of the cleaner body; a second laser emitting a second laser beam toward an upper front of the cleaner body; and a camera configured to photograph the first and second laser beams within a prescribed photographing area.
 5. The robot cleaner of claim 4, wherein the first laser, the second laser, and the camera are sequentially arranged and vertically aligned at the side of the cleaner body.
 6. The robot cleaner of claim 5, wherein the first laser is inclined in a downward direction relative to a side surface of the cleaner body, and the second laser is inclined in an upward direction relative t to the side surface of the cleaner body.
 7. The robot cleaner of claim 5, wherein the sensor assembly further includes: a window provided over the sensor and the sensor module, the window having a prescribed amount of transparency; and a case housing the sensor and the sensor assembly, and the case being mounted to the cleaner body.
 8. The robot cleaner of claim 7, wherein the window includes a transparent window covering the sensor, and a translucent window covering the sensor module.
 9. The robot cleaner of claim 8, wherein a through-hole is formed at a location corresponding to the sensor in the second window, and the first transparent window covers the through-hole.
 10. The robot cleaner of claim 9, wherein the second window includes: a first part having the through-hole; a second part downwardly extending to be inclined at the first part, the second part being disposed to cover the first and second lasers; an extension part downwardly extending at the second part, the extension part being covered by the case; and a third part downwardly extending at the extension part to protrude to the outside of the case, the third part being disposed to cover the camera.
 11. The robot cleaner of claim 10, wherein the extension part is upwardly inclined with respect to the third part so as to not interfere with an angle of view in the vertical direction of the camera.
 12. The robot cleaner of claim 7, wherein the case includes: a mounting frame having the sensor and the sensor module mounted therein; and a cover frame coupled to the mounting frame, the cover frame being mounted in the cleaner body such that at least one portion of the window part is accommodated therein.
 13. The robot cleaner of claim 12, wherein the cover frame is disposed to cover the top and side surfaces of the cleaner body.
 14. The robot cleaner of claim 13, wherein an upper end of the cover frame is located above the sensor, and the upper end protrudes above the top surface of the cleaner body.
 15. The robot cleaner of claim 14, wherein the upper end of the cover frame is formed inclined back and forth to have a sharp shape.
 16. A robot cleaner comprising: a cleaner body including a plurality of wheels and a controller controlling driving of at least one of the wheels; a cleaner head protruding from the cleaner body, the cleaner head having an intake port to suction air containing foreign substances; and a sensor assembly mounted to the front of the cleaner body, wherein the sensor assembly protrude over top and side surfaces of the cleaner body, and an upper end of the sensor assembly protrude beyond the top surface of the cleaner body.
 17. The robot cleaner of claim 16, wherein at least one portion of the sensor assembly vertically overlaps with the cleaner head protruding from the front of the cleaner body.
 18. The robot cleaner of claim 16, wherein the sensor assembly includes: a sensor oriented in an inclined angle relative to side and top surfaces at an upper corner of the cleaner body to capture an image of a front space and an upper space, which are in front of the cleaner body; a sensor module adjacent to the side surface of the cleaner body to sense an obstacle in front of the cleaner body or sense a vertical drop in front of the cleaner body; a window to cover the sensor and the sensor module, the window having a prescribe amount of transparency; and a case accommodating at least one portion of the window, the case being mounted in the cleaner body.
 19. The robot cleaner of claim 18, wherein the case includes: a mounting frame having the sensor and the sensor module mounted therein; and a cover frame coupled to the mounting frame, the cover frame being mounted to cover the top and side surfaces of the cleaner body when at least one portion of the window is accommodated therein.
 20. The robot cleaner of claim 19, wherein an upper end of the cover frame is located above the sensor and protrudes beyond the top surface of the cleaner body. 